How can you replace a hexagon at home?

The hex key can be replaced:

A hex wrench is a common tool, especially in furniture production. It is used to loosen or tighten bolts that have a hexagonal groove in the head.

Sometimes this tool is not at hand and you need to look for a way to replace the hexagon at home.

To fix bolts with outer edges, wrenches are used, which cannot always be used because the edges of the part are damaged in some way.

To unscrew them, you can also use improvised means.

How to replace a hex wrench

Fastening elements of many designs require the use of products with a certain type of head. A special place among them is occupied by bolts made with a hex key.

Very often such products are found in the furniture industry. Here they are worked with using keys type DIN 911. You can purchase them on many construction sites, where their main technical characteristics are indicated.

Main characteristics

A hex bolt is a type of fastening tool, characterized by an internal head in the form of several edges. This allows it to be made with the same diameter as the main rod.

Such bolts are used in various fields:

• the furniture sector is used to fasten several parts into one;
• complete set of plumbing mechanisms. The hexagon can often be found on the mixer, which secures the main handle, etc.;

All types of such fasteners also have a peculiar division according to standard sizes. For each of them, a corresponding key is standardized, often having a curved shape in the form of the letter “G”.

Welding hexagonal shape

Now all that remains is to weld the part into one. (In my case I used a 2.5mm welding electrode)

After this, you need to try on the nut again, and if everything fits, you can fill the cuts with welding. (3.2 mm electrode).

We try to put it on the nut again, because the high temperature during welding can deform the metal.

(This time I additionally tried the blank on the hexagonal protrusion on the filter.)

After this, you can clean up all the excess, making the shape of the part smoother.

We weld the lid

After sanding, place the piece on the sheet of metal from which the strip was made and trace its outline on it.

I chose to draw the line along the inside, adding a couple of millimeters along the edges. But you might want to outline the part around the outside, on the contrary, removing the extra couple of millimeters.

Then we weld the resulting upper part onto the previously made part. (We use 2.5 mm and 3.2 mm electrodes)

Let's check again if everything fits.

Pipe welding

Only after this step can the result of the work be called a tool.

Hexagon alternative

This type of fastener is very inconvenient to use in the absence of special tools.

There are several ways to replace a hex key:

1. First of all, you can use a screwdriver of a certain size. In this case, you should rest its edges on opposite sides of the groove and try to turn or tighten the bolt.
2. Bolt with a set of nuts. They are screwed onto the thread and placed inside the hexagon. In this case, tightening is done using a wrench. It should be noted that bolts and nuts must be selected according to the standard size of the hexagon.
3. As a tool, you can use a triangular file of a specific size or an “asterisk”.
4. If the design allows, you can cut a small hole in the hexagon for a flat-head screwdriver and then work.

It should be noted that unscrewing such a connection is somewhat easier than tightening it properly. For such cases, it is advisable to use a special tool. It is often sold in whole sets, which allows you to select it for any type of fastener.

If you need to remove the hexagon, you can cut off the head and knock out the bolt (if you have access). You can also turn the bolt by hitting a hammer and screwdriver along a certain edge of the product.

All these methods are not universal and can damage the hexagon design, which will lead to its replacement.

Thanks to this video you can learn how to quickly replace a hex key:

Preliminary preparation

First, it is imperative to carefully prepare for the further implementation of the entire complex of events. First you need to prepare all the necessary tools. You also need to select a rod of the highest quality so that it is able to withstand the load that the hexagon takes on during operation.

So, all the most necessary cutters should be at the workplace. Of course, you can’t do this without a lathe. The work ahead is delicate, so you should choose the highest quality cutters. Now it’s time to prepare a stencil that will mark the side face of the hexagon. After all, you will have to make a full-fledged tool from a round shaft. You will need a brush to remove excess iron filings. These are all the preparatory works that need to be done before further work can be carried out.

How can you replace a hexagon at home?

Andrew Taylor (taylor.a), flickr.com CC BY

Fasteners in modern technology are distinguished by significant diversity. These include regular hex bolts and nuts, flat and Phillips slot screws, Torx sprockets and many others. Parts with an internal hexagon stand apart here. Unscrewing them without a suitable tool is quite difficult.

The internal hex spline first patented in 1936 by the German company Bauer & Schaurte. In foreign technical literature, such screws are usually referred to under the brand name Inbus. This is an abbreviation of the German phrase Innensechskantschraube Bauer und Schaurte - a hexagon socket screw from Bauer & Schauerte.

Advantages of internal hexagon

Hexagon socket bolts and screws have a number of advantages over conventional fasteners. Firstly, there is no need to leave space around the head with such a slot for the fastening tool. In this case, you can completely “recess” the screw into the part, which is very convenient for all kinds of drain plugs.

How to unscrew a hexagon: preparation

Whatever the reasons for the situation when the bolt stops unscrewing, the following steps should be taken before plumbing:

1. Before unscrewing the hexagon, to reduce the coefficient of friction, it is necessary to open the bolted fasteners with lubricant such as WD-40, kerosene or brake fluid. You can start unscrewing the bolt 30-60 minutes after application.
2. A stuck bolt can be gently tapped with a hammer so as not to further disturb the thread.
3. If the location of the fastener allows, you can heat it with a gas burner so that the metal becomes more pliable and rust and dirt turn into ash.

How to unscrew a broken hex bolt

To unscrew a protruding hex or star bolt, you can use the following methods:

1. Using a hacksaw or a grinder, make a neat and clearly vertical cut across the screw head. After these steps, you can unscrew it with a regular flat-head screwdriver.
2. Using a Torx star: you need to drive it into the recess for the hex key in the hardware head. The size of the sprocket should be such that its splines do not fit into the hole. Then the hardware is unscrewed with a sharp jerk. It is not recommended to use a Torx with a hole in the center; the sprocket can break off.
3. Before unscrewing the hexagon with torn edges, a drill with drills and extractors is used to drill a hole in its center. After this, the extractor is driven into it, then pulled out with pliers along with a hex screw.
4. Using a drill with reverse rotation, a thin hole is drilled, then a hammer is inserted into it with left rotation and the fasteners are unscrewed. In this case, the rotation of the drill should be slow and the pressure should be strong.

see also

Comments 37

I usually unscrew it with a chisel, start cutting into the outer edge of the head and the bolt comes off. For convenience, you can remove the pulley along with the gear and do this in a vice. To do this you need a 19 12-sided head. Before removing the bolts, it was worth tapping and cleaning the heads...

In general, I broke the nuts, thanks to everyone for the advice. I found a set of 4 star cue balls with 12 angles in the only store in the city. Thanks to the Chinese household goods store. I bought a treshetka open-end wrench for 17. Now I’m looking for one for 13)))

it’s easy if you can get to it with a semi-automatic device, weld a larger nut and slowly turn it...

take drills from 6 to 9, maybe 8 quatit, first drill out the rest of the hexagon, then increase the diameter and thereby drill out the bolt head exactly and so on with the rest, then the pulley is removed from the remaining bolts as if from studs, if you don’t use a gentle tap. After this, the remaining bolts in 99% of cases are unscrewed by hand or with pliers, but even with the worst outcome, you can take a lot of things and make a cut for a slot, etc. etc., but this is most likely not required

If it doesn't work, you'll have to drill it out

I was advised to buy freon in a bottle.

Maybe a little off topic, but for the future - if the bolts are tightened at the service center with a FASHIONABLE pneumatic tool with a blow (and they don’t give a damn with what force), then it’s cheaper to disassemble the assembly THERE, otherwise a headache is guaranteed. It’s not for nothing that regulations on efforts are written. I myself also encountered a similar problem, but I was not always able to cope with such a problem myself:(. Good luck.

This problem often arises when the hex bolt is torn off and it is not possible to unscrew it with a wrench. The causes of this problem may be the sticking effect, displacement of the parts being fastened, over-tightening when installing hex hardware, as well as the use of inappropriately sized keys.

How to unscrew an internal hexagon with torn edges

To unscrew a bolted connection with a through hole, you can use a file. With its help, the hexagonal hardware is bored to the next size and unscrewed with a wrench.

The second way is to use Torx. They can punch out new splines and reuse the hex hardware, but subsequently it can only be unscrewed with a Torx sprocket.

Torx sprockets

In addition, before unscrewing the torn hexagon, you can saw through the internal axis of the hexagonal fastener for a screwdriver and unscrew it. With this method, it is not always convenient to get to the fastener; sometimes its location does not allow the use of a screwdriver.

How to get a Licked Screw?

Let's assume that the head on the self-tapping screw or screw remains, but the slot is torn off, as many craftsmen say - “licked”, rolled. A screwdriver or drill simply breaks off such fasteners. The easiest way to deal with this problem is to use a piece of rubber or any rubberized material.

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How to unscrew a hex without a key

Other ways to unscrew a bolt without a hexagon are as follows:

1. If the size of the bolt is not too small, you can use a chisel or an ordinary hammer: they strike at an angle in the direction of unscrewing the fastener.
2. Method using a spanner or gas wrench.
3. If you have a problem with how to unscrew a “licked” hexagon, you can use a wrench with an attachment. The bolted connection is unscrewed using a hammer mechanism.
4. Method of using welding: a small amount of metal with a nut or any piece of reinforcement is welded to the fastener, with the help of which it is then unscrewed.
5. The extreme measure for unscrewing hex hardware with an internal axis is to completely dismantle the fastener, when cuts are made with a hammer and the fastener is disassembled.

Giving a hexagonal shape

At this stage, it will be more convenient to work if the metal is heated. (I did not maintain a constant temperature and was unable to bend the entire piece in one piece).

How to unscrew a hexagon: preparation

Whatever the reasons for the situation when the bolt stops unscrewing, the following steps should be taken before plumbing:

1. Before unscrewing the hexagon, to reduce the coefficient of friction, it is necessary to open the bolted fasteners with lubricant such as WD-40, kerosene or brake fluid. You can start unscrewing the bolt 30-60 minutes after application.
2. A stuck bolt can be gently tapped with a hammer so as not to further disturb the thread.
3. If the location of the fastener allows, you can heat it with a gas burner so that the metal becomes more pliable and rust and dirt turn into ash.

How to remove a screw without a screwdriver?

To remove a screw without using a screwdriver, you can use a screwdriver. It is important to choose the right tool. It is important that the tip fits well into the groove and is not damaged. If this fails, you should use additional methods.

If you want to remove a screw from a piece of wood, you need to hit the head and then tap the surface each time you apply force. You can also use pliers or rubber band seals.

To get the screw to start turning, it is recommended to use a little lubricant or brake fluid. Kerosene is also suitable for this purpose. In addition, the screw can be heated. This will provoke its expansion and deformation of the adjacent material, which will help to quickly unscrew the product.

How to unscrew a broken hex bolt

To unscrew a protruding hex or star bolt, you can use the following methods:

1. Using a hacksaw or a grinder, make a neat and clearly vertical cut across the screw head. After these steps, you can unscrew it with a regular flat-head screwdriver.
2. Using a Torx star: you need to drive it into the recess for the hex key in the hardware head. The size of the sprocket should be such that its splines do not fit into the hole. Then the hardware is unscrewed with a sharp jerk. It is not recommended to use a Torx with a hole in the center; the sprocket can break off.
3. Before unscrewing the hexagon with torn edges, a drill with drills and extractors is used to drill a hole in its center. After this, the extractor is driven into it, then pulled out with pliers along with a hex screw.
4. Using a drill with reverse rotation, a thin hole is drilled, then a hammer is inserted into it with left rotation and the fasteners are unscrewed. In this case, the rotation of the drill should be slow and the pressure should be strong.

How to unscrew an internal hexagon with torn edges

To unscrew a bolted connection with a through hole, you can use a file. With its help, the hexagonal hardware is bored to the next size and unscrewed with a wrench.

The second way is to use Torx. They can punch out new splines and reuse the hex hardware, but subsequently it can only be unscrewed with a Torx sprocket.

Torx sprockets

In addition, before unscrewing the torn hexagon, you can saw through the internal axis of the hexagonal fastener for a screwdriver and unscrew it. With this method, it is not always convenient to get to the fastener; sometimes its location does not allow the use of a screwdriver.