AP pulley install - stripped bolts
 

I stripped two of the bolts as I was trying to torque them down. I don't know how I'm going to get these out in such a confined space. :( Does anyone have any suggestions on how to get these out?

Everything seems to run fine; the stripped bolts were at least tightened down somewhat, but I would rather replace them for the sake of knowing they're torqued down properly. That brings up another question; has anyone ever ordered replacement bolts? I assume I should just call Agency Power?

so when you try and wind them out they just rotate and don't come out ?

Oh, sorry... "stripped" as in mangled the hex socket of the two bolts; the threads themselves should be fine. However I cannot easily twist them out because they're already kinda tightened on, and a hex#5 bit pretty much just spins around in the socket of the bolts now.

Find an SAE socket that is a little smaller and tap the socket onto the bolt head with a hammer.
Yes this will further damage the bolt head, but who cares, you're replacing it.

To be clear, you're suggesting to use a socket as opposed to a bit, yes? Otherwise, i'd think to use a slightly larger bit.

I guess more stuff is gonna have to come out (battery, airbox tray, intake) to get swinging room for a hammer.

Yes... no reason to drill it out if you can find a way to grip the bolt head.
A slightly smaller socket tapped onto the head should give you enough grip to turn the bolt out.

/\ They are allen head cap screws on the AP pulley

But jons idea can work for a capscrew as well - get the next size up allen key and grind it down to be a tap fit into the holes .....

Damn... shows you how long its been since I've installed an AP pulley!
Thanks for correcting me Brettus.

Generally, I will usually find a pair of vise-grips that will get in there and use those.
Isn't the torque number on those bolts pretty light? My UR's are something like 8ft-lbs on the eccentric shaft and water pump.

Staticlag had a bit of a DIY out there for the install; he quoted 10-12 ft.-lbs.

https://www.rx8club.com/showpost.php...9&postcount=34

Another thing that often works is to tap a Torx head into the hole.......They will often grab quite well in a stripped out Allen head bolt :)

what the heck did you use to tighten them? i found it helpful to use the ball-end hex wrenches to get to them at a better angle.

Once they are hand tight with a hex#5 bit in a socket-bit adapter, I find there is enough room to then use your typical torque wrench to tighten them to spec.

^.................make sure you check them again after a couple of days!

Absolutely. I've been watching the pulley motion before and after driving sessions. So far it seems things are good. I'll check the actual bolts tonight or tomorrow. Regardless, I am on the hunt for a replacement set of bolts.

Go to sears and get stripped bolt tool. It fits over the top they sell it as a set.

Put a shot of PB blaster before trying to stripped nut tool. In future use a little silver locktite, I apply and then wipe down with paper towel to leave only a little bit.