OS 25 FP & 2mm socket head screws

[John Craig]

Trying to disassemble an OS 25 FP  3 of the 6 head bolts came loose with out an trouble.  The remaining three will not budge.  When I put downward & twisting force, I will finally hear a little pop & feel movement. Only to see that the pop was the sharp corners of the Allen Wrench giving way.   

SUGGESTIONS?

[Paul Smith]

You can saw off the end of the wrench and go again.  Maybe with a heat gun this time.

[John Eyer]

You might try Sears stock number 966197 Screw Extractor.  Follow instructions labeled 1,2 & 3 on back of card.   Works great on old Fox 35 Stunts.

[dennis lipsett]

Hopefully you are not using 'allen' wrenches or keys bought at harbor Freight or any of the other bargain stores. They aren't made of any decent metal and will always round out easily when pushed.

[Motorman]

You can use a dremel tool cut off wheel to cut a screw driver slot.

MM

[Brett Buck]

You can saw off the end of the wrench and go again.  Maybe with a heat gun this time.

   Cut off the end, heat it red, then quench it in water. Then try again. If it rounds off again, get a good set (like the relatively inexpensive Bondhus), and you will have no more problems.

     Brett

[rich gorrill]

When removing any screws either allen head or Phillips I hold the engine steady on the work bench insert the allen wrench and give it a sharp hit with a hammer. Sometimes this helps break the bolt loose. It can be dirt or rust holding it, also a good soaking with Kroil or Liquid Wrench helps.

Rich

[Dan McEntee]

   If you have replacement screws ( and you should if you are rounding out the socket also) just drill out the head of the screw. Use a drill a bit larger than the shank of the screw. Drill in until the bit gets to the point where the shank of the screw meets the head of the screw, then the head will pop off. Repeat on the other screw, then remove the head. There will be enough of the shank left above the cylinder to grab with small pliers and finish backing them out. You just need to sure you are using a good quality drill bit, as the socket heads can sometimes be fairly hard.
  Type at you later,
    Dan McEntee

[RknRusty]

Hopefully you are not using 'allen' wrenches or keys bought at harbor Freight or any of the other bargain stores. They aren't made of any decent metal and will always round out easily when pushed.

No kidding. My fancy Horror Freight 16 piece T-handle set was a crappy investment. I've ground the end of my 1/8" wrench so many times it's going to disappear soon.