Stripped CV bolts... help!!

[TumbleBug]

Hey guys, I know some of you have had to had this problem... I was trying to remove the axles form my IRS bug tranny, and I guess the previous owner tried to use a 6 point allen instead of the correct 12 point, to remove them and I have found 3 that are stripped out. Any suggestions on how to remove the remaining bolts?? I tried vise grips, but no luck. Thought about the old hammer & chisel method, but kind of worry about breaking away the head & not being able to remove them at all. What have you guys had luck with??? Any & all suggestions are appreciated!! Thanks...
Wes

[artjr979]

You could try cutting a slot with a die grinder as big as the biggest screw driver you have and then put a vise grips on it or a wrench.

[DailyPedal]

Don't panic...get the biggest vise grips you can and try again. If that doesn't work, and it should, cut the head off with a grinder. Don't worry about the bolts-you should use all new anyway and any other parts that may get jacked-up like boots, flanges or bolt plates are cheap and plentiful anyway.

[TumbleBug]

Thanks guys, I wasn't panicing, I'm not using any of the parts anyway, I'm just trying to disassemble them so I can get them out of my truck by myself without screwing up my back, and maybe still be able to sell the parts if I don't use them in another project. Thanks for the suggestions... http://www.race-dezert.com/vb3/attachments/old/images/graemlins/smile.gif
Wes

[Wayne_Nosala]

I have had great luck with finding a Torqz type driver socket, they seem to
grab stripped socket head screws pretty good by setting them in with a hammer.
I know its NOT Supposed to be the tool for this job, but it has gotten me out of
a jam many times.

[KitRacer]

I've had the same problem many times. I tried to reuse the bolts because they had already stretched and I wouldnt have to retorque as often. Eventually the heads got pretty round. For me, the vise grips never worked. I ended up welding on 1/8" x 1" flat stock about 6 inches long onto the stripped bolt. Then I beat on the end with a hammer and they popped right loose. I think the heat from the weld helped. Then you have to grind the mess off the end of the bolt and take them off with vise grips. Its a pain in the rear, but was the only solution I could come up with. Thats the problem with torquing those bolts to 90 ft/lbs

[Bajatoy]

Along the same lines, I have done this before, find a nut a little bigger than the head of the socket on the bolt, then with a wire feed welder zap it from the inside of the bolt to the nut then let it cool down and turn it off with a wrench. Just like it was mentioned the heat will help shrink the bolt a little bit so get as much weld in there on the bolt as possible.
Good luck!

[TumbleBug]

Thanks a lot guys, I managed to get them out with the help of an extra pair of hands, and a bigger set of vise grips after a couple of persuasion taps with a hammer. I appreciate all of your help.
Wes