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coullstar
Albert Park


Joined: 15 Sep 2015
Posts: 1567
Location: Aberdeen/Torphins


PostPosted: Tue Sep 03, 2019 10:22 pm    Post subject: Caliper Bolt head rounded Reply with quote

So went to change the front brakes tonight and one side done then the very last caliper bolt head has rounded.

Other than drilling and easyout is there any other option? Any tips other then heat and plusgas?
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1999 C2 Coupe - http://911uk.com/viewtopic.php?t=124107
 



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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 8373
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Tue Sep 03, 2019 10:42 pm    Post subject: Reply with quote

A last resort for me would be an easy out with a bolt so long. I would be trying to heat the hub and hammer the next size allen key in if possible, next I would try to weld a nut on the end but it all depends on your facilities. Plusgas/WD as much as possible for as long as possible too.

Some people have had to drill them out and Helicoil
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Chris_in_the_UK
Estoril


Joined: 19 Mar 2014
Posts: 3585
Location: Harrogate


PostPosted: Tue Sep 03, 2019 10:57 pm    Post subject: Reply with quote

Would try the next size up Allen hex socket - drive it in with a decent hammer and soak it overnight with a release fluid. Then use an impact driver/wrench.

Good luck!
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kurlykris
Magny-Cours


Joined: 30 Jun 2014
Posts: 2512
Location: Warwickshire


PostPosted: Tue Sep 03, 2019 11:03 pm    Post subject: Reply with quote

It`s a metric hex bolt, I would try a slightly larger imperial allen key, sometimes I use Torx bits and hammer them in, they all have to be decent quality though Grin

I think the torque on the bolt is 90Nm, so it isn`t going to come out easily Sad
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2006 Boxster S sport chrono
2010 Mercedes E350 AMG Sport

 
  
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Hertsdriver
Spa-Francorchamps


Joined: 12 Nov 2018
Posts: 325
Location: Hertfordshire/London

2004 Porsche 997 Carrera 2

PostPosted: Wed Sep 04, 2019 8:42 am    Post subject: Reply with quote

I have had this happen before on another car... would echo the sentiments above (bang in a good quality large size torx bit), but would also add:
put the other caliper bolt back in and torque it up, it may only be in my head but anything that can help to ease the tension on the bolt you are undoing can only be a good thing right? also I gripped the outside of the head at the same time with a good quality pair of molegrips, and aligned them so that you undo both the mole grips and torx bit at the same time to apply more power. I would also try doing it up first as that often helps as odd as it sounds.
Best of luck
 
  
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coullstar
Albert Park


Joined: 15 Sep 2015
Posts: 1567
Location: Aberdeen/Torphins


PostPosted: Wed Sep 04, 2019 8:49 am    Post subject: Reply with quote

Thanks, all suggestions are what I was thinking. Just wondered if anyone had had more success than others.

Ive ordered 4 new bolts to replace them.

To be honest the discs are okay so Im going to change out pads and then I plan to replace all suspension arms and have a set of coilovers to fit over winter so I'll sort it then.
I'll have plenty of other sized bolts to deal with then!!! Laughing
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Luddite
Nürburgring


Joined: 18 Dec 2018
Posts: 441
Location: Scotland


PostPosted: Wed Sep 04, 2019 9:49 am    Post subject: Reply with quote

Yup my first thought when I saw this was try to hammer in a section of imperial allen key and apply a spot mig weld to keep two together then use an imperial socket on the allen key stub to remove the offending item.

I appreciate you may not have mig welding facilities but you could fit the allen key and take it to a local garage/welder and progress from there... Question

Good Luck.
 
  
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Ghianightmare
Spa-Francorchamps


Joined: 25 Apr 2017
Posts: 353
Location: Dublin


PostPosted: Wed Sep 04, 2019 1:36 pm    Post subject: Reply with quote

Any of the above but regardless of the method, definitely douse it in penetrant and even put a heat gun on it. Also, if it won’t loosen, try to turn it in the tighten direction a tiny tiny bit just to break the torque. Bear in mind it is a steel bolt in aluminum so you don’t want to over tighten. I’m talking about 5-10 degrees here.

Also, after dousing in penetrant, clean the threads sticking out of the housing. These are normally rusted up. The rusted crud is sometimes hard enough to rip out the aluminum threads in the housing as you unscrew the Bolt.

Good luck
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dt4
Monza


Joined: 16 Mar 2016
Posts: 189
Location: Leeds


PostPosted: Wed Sep 04, 2019 2:08 pm    Post subject: Reply with quote

Graham
Have you got a set of Irwin nut / bolt detractors
Heat + plus gas + Irwin
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1975 914 1.8
2000 986 2.7
 
  
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coullstar
Albert Park


Joined: 15 Sep 2015
Posts: 1567
Location: Aberdeen/Torphins


PostPosted: Wed Sep 04, 2019 3:22 pm    Post subject: Reply with quote

Ive got Irwins but there isn't enough room for them on the head.

MOT in about 2 weeks, if it fails then its coming off the road so I'll do it then. If not then it will be a couple of months yet.
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7176
Location: Brighton


PostPosted: Wed Sep 04, 2019 6:41 pm    Post subject: Reply with quote

I would try and undo using a Torx socket .. to be fair that's what i normally use on these allen head bolts .. T55 or T50 i think .. not sure.

Failing that i would try and weld a nut on or just drill out the head , slide the caliper off and then deal with what's left .
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 8373
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Wed Sep 04, 2019 7:48 pm    Post subject: Reply with quote

deMort wrote:
or just drill out the head , slide the caliper off and then deal with what's left .


Another good option as above, remove the bolt head and get a stud extractor on whats left of the bolt, I have removed head stud with one of these plus you can get some penetrating fluid right to the start of the threads with no caliper there.
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kurlykris
Magny-Cours


Joined: 30 Jun 2014
Posts: 2512
Location: Warwickshire


PostPosted: Wed Sep 04, 2019 8:28 pm    Post subject: Reply with quote

Lol, every time I suggest drilling a bolt out, every body insisits that we should throw some fire on it instead Grin Joker
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Marky911
Magny-Cours


Joined: 04 Jun 2009
Posts: 2519



PostPosted: Wed Sep 04, 2019 8:37 pm    Post subject: Reply with quote

^^ Grin

Good luck Graham. If you end up needing to helicoil/timesert it then be careful.
Craig had a loud annoying creak on his car for a while a couple of years back. Turned out that a previous owner or mechanic had had to helicoil the hub carrier for exactly your problem and they hadn’t managed to keep it square.
When Craig was breaking the calliper was actually flexing as the pads pulled it square to the disc.

Remedy - new hub carrier. nooo
 
  
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7176
Location: Brighton


PostPosted: Thu Sep 05, 2019 7:31 pm    Post subject: Reply with quote

kurlykris wrote:
Lol, every time I suggest drilling a bolt out, every body insisits that we should throw some fire on it instead Grin Joker


Drilling is fine .. as is welding .. it's down to what equipment you have ..

I will say welding will burn the paint on the caliper so drilling might be the better option.

Mechanics are lazy anyways .. we go with the easiest option lol .
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My Daughter's Crowdfunding has hit the target see Here

Thank you all so Very much .

She's not going until july 2020 though .



Mechanic

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Now At An Indy.
 
  
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diverzeusy
Suzuka


Joined: 10 Nov 2012
Posts: 1032
Location: Doncaster UK


PostPosted: Thu Sep 05, 2019 8:39 pm    Post subject: bolt rounded Reply with quote

I had this happen to me, as Demort said I drilled very carefully with a 10 or 13mm drill bit, as it approached the calliper the head came away.
fortunately the second bolt came out ok so now the calliper just slid off the headless bolt.
I then got my medium, 10 inch stilsons on the remaining bolt and out it came fine with no damaged threads or burnt calliper wich would be the case if heator welding is invoved.
Great fun these cars, good luck Thumb
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coullstar
Albert Park


Joined: 15 Sep 2015
Posts: 1567
Location: Aberdeen/Torphins


PostPosted: Thu Sep 05, 2019 10:48 pm    Post subject: Reply with quote

That's my plan at the moment,

Try torx, heat and plus gas.
Then drill head and get caliper off.
Deal with stub of bolt.
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kurlykris
Magny-Cours


Joined: 30 Jun 2014
Posts: 2512
Location: Warwickshire


PostPosted: Fri Sep 06, 2019 12:36 am    Post subject: Reply with quote

deMort wrote:
kurlykris wrote:
Lol, every time I suggest drilling a bolt out, every body insisits that we should throw some fire on it instead Grin Joker


Drilling is fine .. as is welding .. it's down to what equipment you have ..

I will say welding will burn the paint on the caliper so drilling might be the better option.

Mechanics are lazy anyways .. we go with the easiest option lol .


Iain, you know that I was just poking fun, you have met me and know my sense of humour Grin

Without guys like you, guys like me couldn`t have awesome days out like we did today at Mallory Park, check out the Zuffenhaus trackday thread which will be updated with photos and I`ll pop some videos up too in the next couple of days.

Porsche People are just awesome and I owe you a big hug next time I pop down your way thumbsup
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7176
Location: Brighton


PostPosted: Fri Sep 06, 2019 7:50 pm    Post subject: Reply with quote

Yup i know .. i just answer every question regardless ..

It will be a while i think till your in my neck of the woods again .. but it's always a pleasure to say hello .. C&C was great to finally meet .. you and i know who we are talking to now .. it makes it more personnel i feel Smile
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My Daughter's Crowdfunding has hit the target see Here

Thank you all so Very much .

She's not going until july 2020 though .



Mechanic

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Now At An Indy.
 
  
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