How to remove an Allen bolt without an Allen key

In the situations where you need to open an Allen bolt but lack the correct size or rounded Allen key in your collection, the need for an alternative method becomes evident. If you’ve encountered this predicament, fret not! In this article, I will present several effective ways to remove an Allen bolt without an Allen key. Keep reading to find out how.

5 Methods To Remove Allen Bolt Without Allen Key

1. Use Lock Pliers or Vice Grip

You can use lock pliers or vice grip to open an Allen bolt effortlessly. The steps are straightforward-

1. Assess the situation and ensure you have the correct size lock pliers or vice grip.
2. Position the tool securely around the Allen bolt head.
3. Turn the bolt counterclockwise (lefty-loosey) using the pliers or vice grip as a makeshift handle.

If you encounter difficulties using this method, don’t worry; you can try alternative approaches below.

2. Use a Grinder and Flathead Screwdriver

This method is widely used and quite common among people.

1. A grinder creates two flat surfaces on the Allen bolt head, forming a slot.
2. Insert a flathead screwdriver firmly into the slot.
3. Turn the bolt counterclockwise using the screwdriver.

If a grinder is unavailable, then explore other methods as well.

Note: Employing this method may result in damage to your Allen bolts, so it’s advisable to consider installing new bolts afterward.

3. Use a Rubber Band With a Screwdriver

Using a rubber band with a screwdriver is another handy method to remove an Allen bolt without an Allen key. Here’s a brief explanation of the process:

1. Take a rubber band and lay it flat over the head of the Allen bolt. Ensure the rubber band covers the bolt’s head completely.
2. Now, insert the tip of a flathead screwdriver into the recess of the Allen bolt. Make sure the screwdriver’s tip fits snugly into the bolt’s socket.
3. With the rubber band between the bolt head and the screwdriver’s tip, press down firmly on the screwdriver while turning it counterclockwise. The rubber band should provide extra grip and prevent the screwdriver from slipping.
4. Continue applying steady pressure while turning the screwdriver. The rubber band’s grip should help loosen the bolt, allowing you to remove it.

Note: This method might not be effective when dealing with a jammed or rusted Allen bolt. In such cases, alternative approaches should be considered.

4. Use Hand Metal File With Adjustable Wrench

Using just a Hand Metal File and Wrench, I successfully opened the Allen Bolt by following these brief steps:

1. Use a hand metal file to flatten both sides of the round-shaped Allen bolt head.
2. Grip the flattened surfaces with an adjustable wrench.
3. Turn the bolt counterclockwise to open it.

Instead of using an Adjustable Wrench, you can utilize pliers or a vice grip to hold the flattened surface of the Allen Bolt. 

5. Use Screw Extractor

If all other methods fail, using a screw extractor is an option worth considering as a last resort. However, it’s important to note that using a screw extractor may render the Allen Bolt completely unusable. Here are the steps to use a screw extractor:

1. Select an appropriate-sized screw extractor that matches Allen Bolt’s dimensions.
2. Carefully drill a small hole into the center of the Allen Bolt using a power drill and a drill bit slightly lesser than the screw extractor.
3. Insert the screw extractor into the hole made by the drill and turn it counterclockwise with the help of a wrench or pliers.
4. Apply steady and gradual pressure while turning the screw extractor until the Allen Bolt starts to move.
5. Continue turning until the bolt is completely removed.

 Allen Bolt is now bound to come out successfully.

Remove Allen Bolt With Rounded Allen Key

Removing an Allen bolt with a rounded Allen key can be challenging, but you can try a couple of creative methods. Here are the steps for each method:

Apply Friction Drops With a Rounded Allen Key

1. Ensure a proper grip by cleaning the bolt head thoroughly.
2. Enhance the grip by applying friction drop to the head of the Allen bolt.
3. Securely insert the Allen key into the bolt’s head, ensuring a proper fit.
4. Apply friction drop to the side of the Allen key where there is a gap as well.
5. Turn the bolt counterclockwise (left-loosen) with steady pressure until it is successfully removed.

Apply Instant Freeze Glue With Rounded Allen Key ( Using Super Glue)

1. Ensure the bolt head is clean and dry.
2. Insert the Allen key into the head of the Allen bolt securely.
3. Apply instant freeze glue around the Allen key, filling the gap.
4. Allow approximately 10 minutes for the glue to set and harden properly.
5. Once the glue has hardened, the Allen bolt can be easily turned and removed.

Both methods can be effective solutions when dealing with a stripped Allen bolt or a rounded or stripped Allen key.

Don’t Do It With Allen Bolt

I cannot comprehend why individuals recommend these techniques. At the same time, it may be moderately effective in loosening an Allen bolt, but it poses a higher risk of harming the surface or the bolt thread hole. With this in mind, I advise steering clear of these methods and exploring safer alternatives instead.

Heat Allen Bolt

Applying heat to an Allen bolt can lead to expansion, making it easier to loosen. However, this method can cause the bolt to become overly brittle or damage the surrounding components, posing safety hazards and potential harm to the overall structure.

Hit With A Hammer

Hit With A Hammer: Striking an Allen bolt with a hammer might seem like a quick solution, but it can result in deforming the bolt head. Additionally, hammering can cause harm to delicate or sensitive materials nearby.

In summary, it’s crucial to avoid these techniques to protect the integrity of the bolt and surrounding components. 

FAQ

Conclusion

Before attempting any method, always prioritize safety, wear proper protective gear, and assess the risks involved. 

I would like to invite you to share your thoughts and experiences in the comments below. If you’ve encountered other ingenious methods for removing Allen bolts without an Allen key, we’d love to hear about them. You can help fellow DIY enthusiasts tackle this common challenge more effectively by sharing your insights.

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