Ooops

 

Ive had luck using a Torx bit that is just barely bigger than the hex size your cap heads are. Put the Torx bit in the stripped hole (ideally it should not go in) then with the bit in a handle or using something you can turn the bit, gently tap the handle or bit with a hammer to help jar the bolt loose while driving the bit into the stripped hex head. Just light tapping as you turn should be enough to break it loose and remove the bolt.

 

Knipex or Vessel vampliers is what i use when i can get to them on a plastic manifold. Break it loose with the pliers, then back it out.
Those bolts are pretty soft, usially you can peen it inward by tapping the bolt head with a punch and a hammer. This denting in willl allow you to drive a proper fitting 5mm bit in to it, and extract it.
The torx bit drove in it works well just be very careful on the plastic manifold. Dont hit it too hard.
Plenty of specialty sockets from irwin, gearwrench and grip tools designed specially for such situations, but tend to be a little pricey.

 

If you have room, try a left handed drill bit. Yes they are a real thing and once you buy a set you'll wonder how you lived without them.

 

Torx bit

Broken bolt extractor you hammer on

Needle nose vise grips

 

At least it is accessible.

 

Dremel with small cutting disc to make a slot to use a long/large flat screwdriver.

 

Vice Grips???

 

1/4 inch cold chisel and a hammer.

About five min mark.

 

You may have room to use these:
Bolt Extractor Set, 15PCS Easy Out Bolt Extractor Kit, 3/8" Drive Impact Stripped Bolt Remover Extractor Socket Set Tool for Rusted, Rounded, Damaged Nuts - Amazon.com
If not, these should work:
Amazon.com: 15 Pieces Screw Extractor Set, Easy Out Bolt Extractor Kit, 3/8" Inch Drive Hex Head Multi-Spline Bolt Remover Kit Tool for Removing Stripped, Broken Rusted Bolts Screws : Industrial & Scientific

 

I would be for trying an EZ-Out or a Torx bit as some others have mentioned. Those bolts are usually deceptively tight and may have a thread locking compound on them as well. If neither of those worked, I'd go for a Dremel and slot the head to use a screwdriver.

 

The problem with an EZ Out is that you are tightening the bolt as you drill the hole. A left handed drill bit loosens it as you drill, usually not needing the EZ Out, but if you do you have been torquing it in the right direction.

 

You may be mistaken on the direction of spin that a screw extractor (EZ-Out) works. Unless the bolt is a left hand thread, a screw extractor will function to loosen the bolt as you try to remove it. Think of them like a tapered, hardened, reverse (left handed) drill bit. They are designed specifically to remove stripped screws and bolts. As you turn the extractor to loosen the bolt they bite harder into the fastener to aid in removal. I had to use a set rather recently to remove a broken bolt on my differential cover. Worked like a charm!

 

You're right, but the DRILL BIT that you drill the hole for the extractor with turns RIGHT tightening the bolt.

 

OH missed that!! I had a Harbor Freight kit with left hand drills so I didn't even equate the drill direction to what you said. Yes Left hand drills many times can get the broken bolt/screw without needing the screw extractor. Since the OP already had a pretty round hole being a stripped Hex Head bolt. they may be able to simply use a screw extractor to remove the damaged fastener.

 

 

This option works if anyone has this issue in the future

 

This option works if anyone has this issue in the future

That is what success looks like! We know the feeling!

 

Question now is did you buy a new bolt yet?

 

I’m too much of a tight wad to go buy a whole kit for one bolt and probably not use again.

 

I've purchased metric allen screws at my corner Ace Hardware.

Yes, I also have a set of left-hand drill bits.

 

If you're like me, the bolt was thrown across the garage at a speed approaching light.

 

But but it’s not the bolt’s fault!

 

Nice! I love the feeling of taking a stripped bolt out. So relieving.