I have a similar problem. I cannot take off onr of my wheel nuts as its the inside hex key type ones amd the thread for the hex key is worn. So know i have no way of taking it off unless i break it. If anyome else can help me too that would be great. Sorry to the OP for jacking the thread as i would like to know how to break it off too.
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U can always take it to a tyre shop. I had these cheap alloy nuts on my car for a month. Were a pain in the ass taking them off and i could feel i was roubdibg off the tapered nuts. This was because they were worn and i was also using the oem key (i didnt have my normal breaker bar on me). I got allmy nuts off except one- it was starting to round and was slipping. Raced down to bridgestone, smaller socket and hammer, whacking for decent 2 minutes and couldnt get it- he just roubded it nore. He tokd me he was busy and to come backnext weekend.
Went to my trusty Jax Tyres to meet up with my mate and told the local guy my problem. He comes out with a couple sockets and a long breaker bar. Got it off in one go! He said its cos the socket has to grab more of the nut, since it was a extended nuts, a long socket is better. I only ever use synchrome sockets, but i immediately went and bought the deep sockets in same sizes just to make sure it wont happen again.
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there are these tools: http://www.transquip.com.au/products...IT-METRIC-14MM
that could:
a) snap it off
b) wedge in and unscrew it... retired/
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Snapping it is a pretty lame would be my absolute last resort.. Another last resort but you could make a small slice straight through the ncentre of the nut with a 1mm cutting disk then use the slice to tap it loose (by unscrewing) with say a chisel or something thats hard enough not to snap off again and cause more probs.. Easy to try could even heat it up a little to expand the steel ( not red hot. And if the nut is very soft it might just warp and bend it with the chiseling) Welding a heavy bolt on like 16mm or something is a pretty good idea, but if you don't have acces to welding gear, and hey if worse comes then the slice will help to break the sucker off.
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