Torx socket broke in screw head!

[nitrofalcon]

New member to this wonderful forum. I'm in a pickle. In trying to remove the lower door hinge, the tip of the star socket (t40) broke in the very stubborn bolt head. I think the paint over the bolt contributed to the difficulty in removing. Any ideas how to get it out? I've attached a picture. I really appreciate any help.

 

[P man]

Try to carefully tap the broken tip to loosen it up then take a magnet and fish it out. In other words get the broken tip centered in the fastener head again instead of being hard pressed against the edges. Make sense?

 

[Danarch]

Same as above. I’d try a few things to try and move it so it would come out easier. If that doesn’t work could drill the center and insert an extractor to back it out.

 

[Jerry Bransford]

That has happened to me, complete with the trail left on the hinge left by the broken stub. I ended up welding a bolt to mine, it came out easily after that due to the immense heat generated by the weld. Any welding shop can do that for you cheaply if you don't have a buddy who welds.

I doubt that particular bolt will come out with an extractor, they're firmly held in by LockTite which needs heat to loosen sufficiently.

 

[cliffish]

You need heat to break the door hinge bolts free

 

[Danarch]

The extractor comment was only to get the broken tip out. The bolt is another issue.

 

[P man]

There is access to the nut plate on the backside correct? Focus your heat there so you don't ruin the paint on the outside.

This is after you remove the broken socket tip of course.

 

[nitrofalcon]

Try to carefully tap the broken tip to loosen it up then take a magnet and fish it out. In other words get the broken tip centered in the fastener head again instead of being hard pressed against the edges. Make sense?

Thanks for the suggestion. Attempted that, but its pretty tightly wedged in there and seems pretty well centered. It's flush with the surface so, can't even get a tapping edge.

 

[nitrofalcon]

Try to carefully tap the broken tip to loosen it up then take a magnet and fish it out. In other words get the broken tip centered in the fastener head again instead of being hard pressed against the edges. Make sense?

Thanks for the suggestion. Attempted that, but its pretty tightly wedged in there and seems pretty well centered. It's flush with the surface so, can't even get a tapping edge.

 

[P man]

Thanks for the suggestion. Attempted that, but its pretty tightly wedged in there and seems pretty well centered. It's flush with the surface so, can't even get a tapping edge.

Try smacking it dead center of the broken tip

 

[nitrofalcon]

Thanks for the suggestion. Attempted that, but its pretty tightly wedged in there and seems pretty well centered. It's flush with the surface so, can't even get a tapping edge.

Looking at my own picture I see now that it may possibly be centered. I'll try again.

 

[JKP]

You will need a punch or the corner of a chisel to get in there to hit it. In the photo, it's not centered, it's wedged in counterclockwise.

 

[nitrofalcon]

Same as above. I’d try a few things to try and move it so it would come out easier. If that doesn’t work could drill the center and insert an extractor to back it out.

Drilling is certainly and option. I've considered that as well. Will give it a try it nothing else works.

 

[P man]

Drilling is certainly and option. I've considered that as well. Will give it a try it nothing else works.

Just fyi I bet that tip is going to be harder than the hubs of hell

 

[nitrofalcon]

That has happened to me, complete with the trail left on the hinge left by the broken stub. I ended up welding a bolt to mine, it came out easily after that due to the immense heat generated by the weld. Any welding shop can do that for you cheaply if you don't have a buddy who welds.

I doubt that particular bolt will come out with an extractor, they're firmly held in by LockTite which needs heat to loosen sufficiently.

Ouch! I pray it doesn't come to that. I think the high heat will probably ruin the surrounding paint and possibly some other things inside footwell? I'll keep in mind if it doesn't budge.

 

[nitrofalcon]

The extractor comment was only to get the broken tip out. The bolt is another issue.

Yes, of course. First thing first I guess!

 

[nitrofalcon]

There is access to the nut plate on the backside correct? Focus your heat there so you don't ruin the paint on the outside.

This is after you remove the broken socket tip of course.

Thanks, Got it. I'll keep that in mind.

 

[Jerry Bransford]

Ouch! I pray it doesn't come to that. I think the high heat will probably ruin the surrounding paint and possibly some other things inside footwell? I'll keep in mind if it doesn't budge.

I am not a great welder but I got the job done without any peripheral damage.

 

[nitrofalcon]

Try smacking it dead center of the broken tip

Thanks. Will try to center it first as you suggested earlier first. and see what happens.

 

[nitrofalcon]

You will need a punch or the corner of a chisel to get in there to hit it. In the photo, it's not centered, it's wedged in counterclockwise.

You are correct sir. I noticed that as well after looking at my own picture. I think this will be my first attempt at it since it seems the safest and easiest. I'm getting out my extra large prayer rug!