Rounded out allen screw replacements

[NoisyDante]

I think there was an overzealous worker back in Bologna.  I can't get the screws out of my handlebar clamp because they're already too rounded out.  I've done thread searches and found some extraction techniques to dry:
- sand dipped allen bit
- torx bit
- soldering iron to melt loctite
- hammering to loosen threads
- JB Weld a bit into the rounded hole

My question is, can I just go to Home Depot or a hardware store to find the hex screws I am to be replacing, or do I need to order them from a dealer?

Thanks

[Ddan]

I doubt you'd find them at Home Depot.  The dealer or  http://www.boltdepot.com/metric-socket-products.aspx

[rockaduc]

I doubt you'd find them at Home Depot.  The dealer or  http://www.boltdepot.com/metric-socket-products.aspx

+1 on bolt depot

[Raziel]

My local True Value hardware has a good selection, not sure why they wouldn't be available at the Home Improvement Box Stores.

[victor441]

drilling might be an option too, have removed stripped phillips screws on old bikes that way (using a bit about the same as the screw diameter), once all the heads pop off the cover/clamp/etc can be removed and the screw can be unscrewed w/ vice grips....the tension is gone so it is generally easy

[NAKID]

I've used a slightly larger torx bit hammered into the bolt before...

[NoisyDante]

Thanks guys, I think I'm going to try the Torx first then go to the drilling.  Now that 'no bike shops open' Monday is over I can call and maybe have some screws expedited to me post haste.

Funny story.  I work in television/film production, and today I recorded the Dirty Jobs guy Mike Rowe.  I figured since he's sort of America's handyman, why not get his opinion?  When were done I said, "Hey Mike, you seem like a handy guy, got any ideas to remove a recessed rounded out screw?"  He recommended the Torx bit.  Very nice guy.

[Slide Panda]

Ha, that's cool. Mike Rowe seems pretty down to earth.. guess you can't get a big head if you job is to try out thigns like making poo pots.

I've found at home depot, the metric selections to be wanting and usually not stainless.

If you get to drilling, you might invest in some left handed bits. The flutes are cut so you spin the drill counter clockwise - this will help things for getting worse, and occasionally back the screw out.

[DesmoTull]

Fastenal is another great choice.  I recently found out about one near me in Peabody, MA.

http://www.fastenal.com/web/products.ex?N=999600040+1199896117&Nty=0

[gage]

I think there was an overzealous worker back in Bologna.  I can't get the screws out of my handlebar clamp because they're already too rounded out.  I've done thread searches and found some extraction techniques to dry:
- sand dipped allen bit

Don't use sand try valve lapping compound

[NoisyDante]

Thanks for all the great ideas.  I ordered 4 screws from boltdepot, and then found an obscure local shop happened to have 3 screws in stock.  At least now I'm prepared for the next round.

[64duc]

  I always use a hammer powered impact driver to loosen allen head screws. works great. Just don't buy one from wallyworld. Pay the money and get a good one from Mac, Matco or the like. I have a K&D Tools driver that I have had for 40 years.

  I also got replacement screws from Ace Hardware.

[scott_araujo]

I've used a slightly larger torx bit hammered into the bolt before...

This worked for me on my last allen that stripped.  Also, check local and Ace hardware stores.  They often have a better selection than Home Depot of Lowe's, etc.

Also, try to get plated bolts and stay away from the black ones.  The black ones are high carbon steel and rot like a pear when they get wet.  Since the bolt heads face up they collect water if the bike gets rained on and rust quickly.

Scott

[NoisyDante]

I just got some original OEM allens in today, the BoltDepot ones should arrive tomorrow.

Would it be an idea to treat these with some sort of water protectant?  Or might one expect OEM parts to not need this?

[Ddan]

The OEM ones are probably zinc chromate plated, so they will be moderately weather protected.