So I bought the Alta Intercooler Air Diverter and began putting it on myself (not exactly mechanically minded, but this looked easy enough). Not having the correct tool for the job didn't help, but I was in the mood and didn't fancy running out to buy the correct one. So I used an allen wrench instead of a star shaped thingamajig and succeeded in stripping the star on the head of the bolt until it is now almost perfectly round.

Any suggestions on getting the little sucker out? In case I haven't explained properly, these bolts are the ones on top of the supercharger.

My next question will be, how do you order a new bolt (or three) without having to look like an idiot and show the damage to the dealer?

To make this story complete, I let the allen wrench slip out of my hand and it dropped down into the fan. As you might know, the fan is plastic and I could just imagine what damage the wrench would do. So...I had to jack the car up and remove half the underside so's I could get my fingers in and retrieve it. Two hours invested and nothing accomplished.

And then people wonder why I don't normally even tackle oil changes on my own.

Ken

 

You can try getting the actual torx driver and use it in an effort to get the bolt out, even when partially rounded out, the torx will grab into the outer points if there is a little bit left.

If the hole is totally rounded out, you can cut a notch in the bolt head with a Dremel tool (best), hacksaw, or a file (worst) and use a large straight bladed screwdriver to remove the bolt. If there is enough of the bolt head protruding, you can sometimes grasp the edges of the head with a Vise-Grip plier and get it out that way. Drilling the bolt out is a last resort if any of these methods dont work.

 

Thanks Greatbar. "Torx" that was the word I was looking for! I'm off to Sears now. Looks like I've got another two hours spoken for tonight when I get home.

Ken

 

If 'Bear's ideas don't work, you can fall back on a variety of bolt removers like these:

 

Okay 8 Ball will do. "Craftsman" too. Right, 'now' I'm really off to Sears.

Ken

 

Whenever I'm stumped, I turn to the Dremel tool first. It's my best friend.

 

... and a torch - watching the bolt heads melt is tons-o-fun ...

 

I appreciate all of this feedback. Thanks. I haven't tried removing the bolt yet as I'm waiting on receiving the special order 75 cent replacement from Mini first(ordered 4 just incase). So which Dremel and attachment am I looking at buying for this job?

Ken
ps I bet I am the only person in history to have walked out of a BMW dealership after spending just $3.24. It could have been 81 cents if I wouldn't have splurged.

 

They are probably snickering still at the fact that you spent so little.

As for the tool, I have a couple older corded tools that work fine, plus a 9.6 volt cordless version which is very handy.

This page at the Dremel site has the cutting disks that I use. Often I use the 426 and 540 cutoff wheels for slotting stripped bolts. You will need a mandrel for these. All of the items can be found at your friendly hardware store like Home Depot or Lowes.

Cut a notch across the entire head of the bolt, and use a large flatblade screwdriver to take it out. Rapping the bolt head with a hammer slightly will help to break the bond of any corrosion that might be present (rainwater coming into the hoodscoop tends to rust these screws. Applu a little bit of oil to the new ones when you replace them to prevent them from seizing again).

 

Just to finish this all up...using a Torx did the trick. As Greatbar had said, there was apparently enough of the star left for it to grip and come out. I still replaced it with one of the 75 cent new ones though. If anybody else runs into the same problem, I have 3 spares and will ship them anywhere in the US for $1.25 apiece plus shipping and handling. Hey, I've got to cover my storage costs.

One of these days I'll get around to writing about whether it's even worth messing with the Alta Intercooler Air Diverter.

Clue: It's not.

Ken

 

Glad it all worked for you. Not all of us Mini motorers are Tool Heads. I would take the extra bolts off your hands but I have trouble even opening my mail.

I once did an oil change on an pls Saab i owned. Was so proud to have drained the oil and changed the filter.

When adding the new oil I was surprised as to how many quarts it was taking. Seemed I had forgotten to replace the drain plug.