My Ragley Big Al Derailleur hanger starts creaking once a year, I took both fittings off the frame earlier to clean and retighten. Both fittings (drive side & non drive side) were very tight, I undid then both and cleaned, refitted using some blue thread lock... unfortunately I managed to strip the head on one of the 3mm Hex fitting bolts on the non-drive side when doing it up. I know the easy option is just leave it as it the non drive side, but I want to remove the bolt and put a new one in. I have tried the usual tricks and am trying one last option of gluing a hex key in with metal bond (6hr cure time), not sure this will work. I guess next option is a good bike shop to try and drill it out ?
Have you tried hammering in an oversized Torx bit?
*im a bodger not an engineer, so you’ll probably get better suggestions.
Have you got a sharp punch/ 1mm drill.
Can you drill (or punch) an indent on the face of the bolt head near the side and then by putting the punch at a sideways angle into the indent gently punch the bolt round in the undo direction by tapping it with a hammer. (Could poss do same with a sharp chisel on the edge of the bolt head).
I used that technique to get out the thread of the outdoor tap when the tap head froze off leaving the tap thread stuck in the pipe.
Have you tried hammering in an oversized Torx bit?
That's the new plan if the metal weld fails, which I think it will as there will be too much rotational torque. What size Torx would you try on a 3mm?
A TX 20 has an OD of 3.3mm, A TX 25 has an OD of 3.75mm, use whatever fits best, Id buy yourself a decent set of hex bits to use as it is easy to cam out on small bolts whilst using poor quality Allen/hex keys
Don't attempt to drill it out, you'll never find the centre of the bolt and you'll damage the threads.
Punch and then drill from the other side. The drill will dig in and unscrew the bolt. Just be careful to punch the centre of the bolt.
the heads stripped or the thread?
if the head, tighten the one next to it up to get some extra torque on it then hammer in a torx or flat head and get it out with that
Have you got access to the back of the bolt, ie can you see the non hex end of the bolt? Is it a through hole? If so this makes things much easier.
Using a drill smaller than the tapped hole, so that you dont **** the frame threads, drill the bolt from the back . Usually what happens is the drill bites into the bolt and the grip the threadlock has on the bolt is weaker than the bolt material, and the bolt spins outfrom the back ( hence tbe need for a smaller drill than the threaded hole!)
Make sure you use a sharp or brand new drill.
Used this method loads of times to remove broken or seized bolts on through holes.
Drill the head off. Unscrew the shaft with pliers.
Or, just leave it alone. Your gears still function so ignore the creaking and just ride the bike.
dremel with cutting disc and cut a slot for a flat screwdriver into the head is my current preferred method.
I’ve had plenty success with the hex bolt extractors
There’s slightly bent and when using they catch better
I tripped the head on a frame pivot bolt and these tools have gotten out a few rounded bolts
Destruction of the screw would be my last resort as the remnants of the head will provide you with something to get hold of. An oversized torx bit or slotting with a dremel as suggested further up the page. If there's loctite on the threads some gentle heat will help soften its hold on the threads. Good luck.
And the winner was the kettle and Mr Hacksaw! That proved to be a really tricky job! I tried drilling out the bolt from the other side, but the brand new Draper drill bit (3mm) was hardly scratching the surface, these must be hardened bolts. No chance of getting a drill in the Hex fitting side due to the chainstays, so an "easy out" was not an option. I stopped drilling as it seemed like a bad idea and went for cutting a hole through the bolt head with a hacksaw and a flat head screwdriver, that was not easy as you need to go pretty deep or you just strip the new hole.
Frame is unmarked, that's some heli tape in the photo.
Good result, well done
Good stuff. That'll be a relief!