How To Remove Rounded Bolts

[rcmadawala]

Hi guys. My car is having a rounded caliper bolt. After having couple of failed attempts to remove it, now It looks like this.

 

When i search regarding this i found out that there are special tools designed to deal with rounded bolts. For an example,

 

 

Also some alternative methods 

So my question is do i really need that kind of tool and if so a place to buy them?

Also is it safe to do alternative methods to it ?

Thanks

Edited October 22, 2016 by rcmadawala

[peugeot407]

Try using  Locking pliers. Before applying torque use a hammer and tap the bolt gently to break the diffusion weld between caliper and the bolt. 

Scotty Kilmer  guy is a US version of makabass. 

[Rumesh88]

You will have to use a chisel and a hammer and tap on the to turn the bolt. Of course be prepared to replace the bolt.

[rcmadawala]

13 minutes ago, peugeot407 said:

Try using  Locking pliers. Before applying torque use a hammer and tap the bolt gently to break the diffusion weld between caliper and the bolt. 

Scotty Kilmer  guy is a US version of makabass. 

ha ha. heard that too

[rcmadawala]

44 minutes ago, Rumesh88 said:

You will have to use a chisel and a hammer and tap on the to turn the bolt. Of course be prepared to replace the bolt.

Yeah I'll need to replace the bolt. Will wood chisel work on this ?

Edited October 22, 2016 by rcmadawala

[Davy]

You can also try using a file to flattern two opposite sides of the bolt so that a smaller spanner can be used to remove it. Will probably take longer than the chisel and hammer, but lower risk of the bolt breaking off IMO. This will only work if you have enough space around the bolt to manoeuvre a file. 

[Rumesh88]

On 10/22/2016 at 9:09 PM, rcmadawala said:

Yeah I'll need to replace the bolt. Will wood chisel work on this ?

No not a wood chisel because material is too brittle. Use a small chisel made for masonry purposes or an old flat-head screw driver shank. Another method is to weld a rod on to the head and use the rod as lever. Although the heat in this case may destroy the rubber parts around, it would definitely loosen the bolt.

[Ripper]

since the location is relatively easy to reach, i would just weld a piece and get it out. just took one out of the truck last weekend. home made t bar welded on to the head of the bolt and voila. the heat from the weld also helped loosen the bolt further.