Help, stripped allen head

Rebuilding the brake calipers. I was removing the allen head screw that holds the pads in the front brake, and it came out about 3-4 threads and locked up. wouldn't go either way. I had soaked everything with break free for about 45 mins before starting, and it finally stripped the allen "hole" out. I tapped in the next size wrench and it stripped out too. Any ideas? Thanks in advance.

 

i would cut in a deep Philips or Flathead or you can us a pair of Vice Grips needle nose or traditional and when working it out if you think the bolt is gettting hot and might snap take a break let it "cool off"

 

Don't know why it locked up so suddenly but perhaps if you could get a dremel in there & cut a screwdriver slot into it & give it a gentle "persuade" with an impact wrench?

I'd be wondering though what caused it to lock up so tight & trying to rectify this too, as you don't want to damage the caliper forcing it... perhaps localised heating may help too/

EDIT-: beaten to the punch! What he said ^^

 

The pad retaining pins on the 650 Turbo/750 Maxim calipers is a BEAST, they are next to impossible to break free and then still require quite a bit of torque to remove. LOTS of penetrating oil, judicious application of heat on the caliper body, and a cheater bar on the allen key wrench is what typically works (lots of bad words help, too......) .

I've literally had to apply almost 100 ft-lbs of torque to break those things free. It's just a poor design on the caliper, the pin, or both.

 

TRY KROIL TOO!

 

The main problem here though is the stripped out allen bolt head :cry: I don't know if the dremel slotting idea would work now you mention up to 100ft/lbs though :? Must be worth a try?

 

This is why i use antiseize when i put stuff together. good thought for when you get it out.

 

Weld a nut to the head, slip a socket over the nut, use an impact wrench (the hand driven kind by pref). The heat from the welding helps break the bolt free.