Bolt Removal HELP [CAT Shield]

I installed a CAT Shield last summer and was trying to remove it today to Fluid Film the truck. The left-side set of 5mm hex bolts came off no problem, however, the opposite side [drivers] did not. You might be able to tell from the pics the hex has started to round-out. Before I honk this up anymore might any of you have a remedy to remove these? I suspect I will change these out to a hex-head bolt. Thanks in advance for any help.

 

Cut a line and use a flathead

 

Penetrating oil?

 

In a pinch I've been able to hammer in a similarly sized Torx bit with a 3/8" drive . Hit it with a little penetrate oil then put some MAPP gas heat on it for a bit and immediately try an turn it. If you do get it out, put some anti-seize on the replacement(s) bolts. If it's near heat, use the copper anti-seize.

 

Find an easier target to steal catalytic converters from

 

Ya no kidding. First post and all .

 

One of my favorite tools, add what ever type tip socket you need allen/socket/screwdriver bit...
https://www.ebay.com/itm/313247055902?epid=668766110

https://www.protoindustrial.com/en/...-3|8"-Drive-13-Piece-Hand-Impact-Driver-Set-/

 

Funny enough...I've got the same issue.

I put a hex bolt on my Talon and son-of-a-gun, I over-tightened the darn thing.

Anyway, it's been suggested to "cut a line" and use a flathead to remove.

Also, using a chisel to cut the top off and then drill out the screw/bolt.

I haven't done mine yet and I don't need to remove it just now, anyway...

 

Cut the bolt in the middle with a saw blade -deep enough so that you can use flat head. I've done it before with hand several times.

 

Penetrating oil like PB blaster or Kroil

Heat

Hammer in next size torx bit

Cut slot for flathead

Sell truck

That would be my order of events.

 

No need for selling the truck. He can park the truck somewhere in LA and the CAT thrifts will easily remove it for him.

 

Here's my blurry pic. And yes, it's my truck! lol

 

Cut a slot with a grinder. Use a screw driver.

 

Tapping a few ties with a hammer lightly will often free up the bolt more than penetrating oil. My Hex drain plug (10 mm on the front diff) was very stuck and penetrating oil had no effect. AMD suggested tapping a few times with a hammer and it came right out with ease. Then you can put a new bolt in when you put your cross bar back in.

 

I didn’t like those bolted from the start so used stainless hex head bolts with a liberal coating of Never Seize.

 

OK, I'm not a pro but I would do it in this order(disregard any other responses):

1. definitely get that 3/8" hand impact driver. These are AWESOME, as it impacts and turns at the same time(best chance to cleanly remove any hard to remove items). Hit with penetrating oil, Tap in a slightly larger torx bit with a regular hammer, then hit the impact and it should come loose.

2. If it doesnt, get a good chisel, cut a small slot only one side of the head and smack it hard (towards the left) with the chisel. It should pop loose. Better yet, ive had it work with a roto hammer or an air chisel.

3. if none of those work weld a nut to it and itll come off.

I almost guarantee you can get #1 or #2 to work.

 

That is absolute worst case scenario. Never loose that head if you have the ability to keep it there. Welding a nut to that head would be the easier/safer thing, even if you dont have a welder.