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How to remove a rounded-out bolt?

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Old Aug 4, 2009 | 08:36 AM
  #11  
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Kbore
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Try my burr method- it works about 90% of the time unless the threads are rusted or loc-tited: grind the face of your torx bit so you get a nice burr (only 1/32" or so). Tap the bit (as in with a hammer), burr and all, into the screw head. The sharp edges will bite and the excess burr material will fill the gap. Works with torx and phillips!

I flatten the ends of all my allen and hex bits flat occasionally as they will wear to round with normal use. Just dont get it too hot....
 
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