Rocker removal striped allen

[OldTee]

The allen head 5mm gave way to the stronger allen wrench and now is nice and round. The 8mm does not have much purchasing and the end slips on the allen.

This is the Intake for Cyl 1 on an 87 Carrera. I am thinking about drilling the 8mm side but I am worried that the bolt is very hard. All the rest of the rockers came out without much complaint.

Ideas:
Pull the heads with cam in place? Then what?
Drill the 8mm plug side? What size drill bit?
Cut off the head of the 8mm plug with a Dremel? Risk damage to boss.
Weld a bolt head into the 8mm and twist off?

What would you do?

[Scott R]

I had a stripped allen, probably done by the PO, anyway I tack welded a cheap allen socket to the bolt where I could. It came right out after that

[tom1394racing]

I've drilled these out successfully a couple of times. I used a bit that was slightly larger than the ID of the large Allen nut to disengage the nut from the bolt. This ruins the nut and bolt but preserves the rocker shaft which then taps out just like the others.

[OldTee]

Thanks, tomorrow is the day.

[North Coast Cab]

Try a 12 point socket wedged in there. If not, removing it with the head off and on a nice work bench will help.

[squidmarks]

Like Tom, I recently drilled out two of these successfully. You can drill either the allen head side or nut side (whichever is easiest to access). If you drill the nut side, make sure you use a center punch on the end of the bolt to help your bit find the center of the bolt. You'll know when you've drilled far enough as it will pop apart.

Geoff

[OldTee]

Got it. Drilled a small whole in the 8MM end, followed by a larger drill. That let the 8MM allen sit further in the recess. Used a small impact wrench with the allen and that broke loose the 8mm nut enough to push it thru the boss. Thanks for the help.