OH S&%T! I stripped a head bolt... HELP!

[Richard Quinlan]

OK
  I am in the process of getting the valves replaced on my 1.8T.  Before
I wound up buying the special bit to remove the head bolts, I had tried a
Torx 50 bit, which fit well, but was *just* slightly undersized.  I tried it
on 2 bolts, and as soon as it popped from one set of teeth to the next, I
stopped.  (Although I tried it on 2 bolts).

So tonight, I’m using the right bit (which is called a tri-square head, 12
point, fitting inside the bolt head), and I get 5 bolts out before I try the
ones I had previously tried the Torx bit in.  As soon as I put some torque
on it, it stripped around inside the bolt.  The bit is not damaged, but the
teeth inside the bolt head are rounded.

So now, does ANYONE have an idea what I can do to get the bolt out?  It’s
under ~55ft-lbs of torque, and in a round hole ~1” deep, about ¾” across, so
getting vice-grips or something on it is out of the question.  I had thought
a screw extractor set might work, but these bolts are pretty beefy looking,
so I’m not sure if that would work.

This was my LAST step in this removal process
.  Grrrrrrrrrrr!!!!
Rich Quinlan

'01 Toyota Tacoma S-Runner in Black - loaded, soon to be delivered!
'97 Audi A4 1.8tqms in Pearl - More mods than you can shake a wastegate rod
at

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