I managed to strip 3 of the 4 hex bolts on the fender support cover that I needed to remove in order to install an Easy Bracket kit. The bolts were from the HD docking hardware kit for my sissy bar. I don't know what the heck kind of locktite or cheap steel Harley used but those things stripped super easy without giving me much of a chance to get them out. I've already tried hammering in a larger hex bit with no luck. The metal is so soft it just strips right away. I'm thinking of going tomorrow and getting an easy out kit unless somebody has better ideas.

 

Easy out
Grind a slit in the bolt and use a flat head.
Hammer a torx bit into it.
tac weld the bit onto it.

Couple ideas.

 

If your talking about the Strut Bolts then get a set of Bolt-Outs. Sears has them...


http://www.sears.com/shc/s/search_10...p17=bolt%20out


Worked for me on some other stripped bolts on my bike...


Mike
NY

 

I use a screw extractor set made by Ryobi (available at Home Depot). Step 1, drill pilot of specified diameter. Step 2, insert screw extractor and twist with wrench.

http://www.homedepot.com/buy/ryobi-5...et-326387.html

 

Dude, I had the same exact problem trying to install my baggertail mounts. I have the detachable luggage rack/backrest and what I did was tak a 3/8" drill bit and drill the mushroom part of the bolt completely off. Then you can remove the docking hardware leaving about an inch of the bolt sticking out of the strut. Then clamp vise grips on it and loosen it. Harley uses a yellow thread locker and it holds like a ****. Ace hardware carries an exact match for the chrome bolt. Cost me $4.20

 

Thanks for the replies. I'm going to go tool shopping tomorrow and add some more to my collection I guess. One thing that is still bothering me is that they stripped so easily. They started stripping out almost right away. Is that just due to crappy steel or is my technique seriously wrong? I was using a brand new craftsman hex bit so I'm pretty sure that wasn't the problem.

 

Yup, they're a PITA to get out. If I recall correctly the MoCo uses red locktite on them, or at least that's what mine had. A little heat, a little patience, and some hard cranking got mine out.

 

Deluxe guy that sounds like a good idea. I don't even need the bolt anyways since new longer ones came with the Easy Bracket kit. I started to think that maybe I needed a special 3/8 inch drill bit but then I remembered how soft and crappy that steel is.

 

I went through 4 bits, but mine were old. Be real careful putting the new bolts back in. I crossthreaded one but luckily was able to crank it down tight. The threads on the strut move around a bit and you have to be careful to get it started right...

 

I did the EXACT same thing when I installed my Easy Brackets. They all stripped immediately no matter what I did. Gforrest2 is right about the red loctite. Took me half a Saturday, a lot of patience, heat, and vise grips to get them off. They were toast when I finally got all of them out. Everyone's suggestions are good, just see what works for you. Good luck and stay vigilant!