Stripped TP55 Bolt - how to extract?

[nyu1]

I did it. I went to install my megawatt sliders and on the last TP55 bolt, I stripped the head. Who uses a Torx Plus bolt for this anyway?! The damn thing is so soft and strips so easily.. I tried angle grinding it so that I could use a prybar as a flathead to unscrew the bolt. No luck. I have the drivers side installed, but that last bolt seems to be welded in…

I’m honestly unsure what I should do now.. I ordered a replacement bolt from EV Sportline in case I’m actually able to get the damned thing out.

Just waiting on the bolt extractor kit to come in so I can give that the old college try.

Anyone have any experience with this? I saw some older threads about it but nothing I tried from those posts worked.

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[SolartoEV]

Do you have a welder?

 

[FooF]

https://www.knipex-tools.com/produc...a-water-pump-pliers-1000v-insulated/8701400US

 

[SolartoEV]

A heavy duty pair locking vice grips and some heat on it.

 

[shamoo]

I don't think that Knipex or some hefty vice grips mentioned above will be strong enough to get that out if a Torx was stripped.

Welding a bolt on or some bolt extractors (the kind where you drill out and reverse thread) would be your best bet. I've gotten some real stuck things off with the latter. Just be careful not to damage the thread.

 

[FooF]

I don't think that Knipex or some hefty vice grips mentioned above will be strong enough to get that out if a Torx was stripped.

Welding a bolt on or some bolt extractors (the kind where you drill out and reverse thread) would be your best bet. I've gotten some real stuck things off with the latter. Just be careful not to damage the thread.

Not sure it is a good idea to be welding on an electric vehicle?

 

[UnsungZero_OldTimeAdMan]

Guessing it'd be more productive to try heat + extractor (EZ Out) or welding a sacrificial bolt or socket.

Not sure it is a good idea to be welding on an electric vehicle?

No different than welding on a a ICE with electrical component/systems. You wouldn't be passing current through those components. You're using electric arc to melt a welding rod and bond one metal to another.

 

[CrazyOne]

Take it to a machine shop. They will probably remove it in 15 minutes or less.

If you don't want to do that, I would do things in this order.
Hammer it. This loosens it. This works magic sometimes. Don't over do it though.

Use some technique to extract it. I once cut the head and used a flat head to remove a hex bolt from my motorcycle.

 

[dleepnw]

Same thing happened to me installing running boards. Not sure if you tried this yet but one trick that worked for me is to take a small piece of aluminum foil, place it in the stripped bolt and that should give you enough grip to remove.

I'd replace the stripped bolt with a new one as well. No sense putting that back in.

 

[captainjp]

Not sure it is a good idea to be welding on an electric vehicle?

I concur. I wouldn’t chance it. Using the chassis as your ground is a bad idea. Maybe some penetrating oil?

 

[Spork8]

Same thing happened to me installing running boards. Not sure if you tried this yet but one trick that worked for me is to take a small piece of aluminum foil, place it in the stripped bolt and that should give you enough grip to remove.

I'd replace the stripped bolt with a new one as well. No sense putting that back in.

Second this - aluminum foil worked for me when a TP55 bolt was already stripped from the factory.

 

[nyu1]

Do you have a welder?

I don’t but I have access to one— won’t I need to disconnect power in order to weld a nut onto the bolt?

 

[DuoRivians]

I think bolt extractors should work well on them. There is still some grip which the bolt extractors should be able to grip onto

 

[RivnSoon]

I did it. I went to install my megawatt sliders and on the last TP55 bolt, I stripped the head. Who uses a Torx Plus bolt for this anyway?! The damn thing is so soft and strips so easily.. I tried angle grinding it so that I could use a prybar as a flathead to unscrew the bolt. No luck. I have the drivers side installed, but that last bolt seems to be welded in…

I’m honestly unsure what I should do now.. I ordered a replacement bolt from EV Sportline in case I’m actually able to get the damned thing out.

Just waiting on the bolt extractor kit to come in so I can give that the old college try.

Anyone have any experience with this? I saw some older threads about it but nothing I tried from those posts worked.

Take the next size up torx bit. Use a hammer to gently tap it into the stripped head until it seats nice and tight. Then use a ratchet with a socket that fits the bit and apply all the pressure you can while loosening it.
If that fails, get a sharp chisel and tap to the left with a hammer to loosen the bolt.
If that fails, buy left turned, or opposite direction, drill bit. Apply lots of pressure while gently drilling it. The goal is the get the bit to bite hard enough to loosen the entire bolt out.
Lastly, just drill the dang thing out.
Ok, done with my Rivian public service for the day!

 

[nyu1]

I’ll give all of these suggestions a try! I appreciate everyone’s suggestions/help! I love this community!

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