Removing a hex bolt that has been rounded

[Sorekiwi]

Now, I would have thought you'd put it in your fancy cnc controlled rotary table and cut a new hex on it! 

[raynerd]

HAha ... I would, but firstly it was so rounded that I`d have to take it down significantly to get a good shaped bolt on it. Secondly, I use to think people were really lazy for saying things like this but I`ve not had much shop time lately with work and such, so I`d much prefer to spend my time on one of my projects for the sake a £5 for a new one!

[andreas]

Hmmm....Kvom said it   I do that a lot on truck differentials and gearboxes draining screws,and sometimes it comes out by hand(make sure its cold!!!) Something you have to be careful is the ground lead,if you don`t want to mess electronics on the bike....Ground as near as possible were you going to weld. It`s also wise to remove the battery and short the terminal cables together while welding    

[bry1975]

Are any of you chaps into cold heading bolts?

[doubleboost]

Whenever i weld on a vehicle i put a surge protector across the battery (saves blowing ecu,s)
On most modern stuff you are going to run in to trouble disconnecting the battery
John