What I do in desperate cases like yours is use a slightly larger English
size allen socket bit. 1/4" with a 3/8 drive. Take a file and bevel the
tip edges of the 1/4" so it will start into the 6mm hole. Then with a
long extension or a stack of extensions to make a long one, pound it
into the CV bolt head. HARD! again and again, until it may never come
out. Then unscrew the bolt.

Sometimes I end up unable to save the tool for next time since it is too
stuck in the ruined bolt.

Mark

J Stewart wrote:
> Thanks for all the replies, folks. I'm now down to just one outer bolt that is rounded and won't come out, the other one I was able to clean out a little more and tap the hex socket a bit deeper and it came out. As things turned out, I didn't have time to finish it today, so what I have right now are the old CV joints with the new star head bolts, except for the one stripped one, so I am in a good position to start this job again next weekend and get it done.
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> Jeff Stewart
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