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Cycleracks install nightmare

2144 Views 8 Replies 6 Participants Last post by  DonBenito
Got my rear Cycleracks rack today and couldn't wait to get it installed.

The right hand allen key bolt (from the top of the passenger footpeg bracket) was a little tight, but it gave in easy enough and backed right out for me.

The left hand allen key bolt though, different story. It turned a cheap allen key into a corkscrew without so much as budging.

I got my nice craftsman allen key set out and I was torqueing it so hard that I thought it would break. Afraid that it might break and slice open my hand, I grabbed it with some vice grips.

The vice grips gave me just enough leverage to completely strip out the hexagon! Allen keys don't work so well in a circular hole.

So, drill and extract it was! Except, the bolt is harder than the Irwin extractor screw I bought at Ace Hardware, so the bolt in turn stripped the threads off of the extractor screw!

I took the cheap extractor back to Ace, and strolled next door to Autozone to buy a harder extractor.

The high carbon extractor had plenty of bite into the relatively soft bolt, and just enough brittleness to snap in half as soon as I put a little muscle into turning it!

So now I have a soft bolt seized up in my left passenger peg bracket with an incredibly hard high-carbon steel extractor tip lodged in the center of it that I have no way of drilling out.

The only thing I can think to do now is ride my TW200 to a local machine shop and let a professional take a crack at it.

If anyone else has a better (read- cheaper!) suggestion I'm open to ideas!
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A 09 with the same rack is on seattle craigs.

sorry but ,I have the same problems sometimes.

Somebody call Homeland Security! Looks like we've got a hijacker on our board!
Sorry Don, no help here, at this point. I had the same experience with one of my allen bolts when I installed mine. I quit quickly and used my impact driver and an allen bit and even then it took probably 7 hits to get it to break free. PITA. You have my empathy my brother.
You'll love the rack when you get it on.

It's good to know I haven't been the only one with this issue.

Thanks to Rich too.

I've been wanting a good excuse to buy a dremel set anyway, and the impact driver is like another 10 bucks so I guess that's justifiable. I've broken more than 10 bucks worth of extractor bits today!

If worse comes to worst I suppose I could spring for a diamond carbide bit and drill out and re-tap the whole thing.

I might just get a whole bunch of new tools out of this situation!
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Thank you everybody for the advice!

In the end I think it was a combination of letting penetrating oil soak in for a few days, some loosening effects of impact pressure, and leverage from securely clamped vice grips that got the job done.

See the pics in Cycleracks Success!
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