lower damper rod retaining screw stripped

Hey Guys,
Stripping down front forks of a XJ900RN.
The first one was no problem to do. I was even at that moment still unaware of the tip of holding the damper rod from inside so that the lower damper rod retaining screw can be loosened.
On this first fork, the lower damper rod retaining screw did seem quite tight but once I got the allen key in there and applied leverage, it came undone without a fuss.




But the second one is not so.
In fact that lower damper rod retaining screw is really stuck in there!
In my efforts to loosen it I stripped the bolt head!
Aw Shit!
Now what to do:

First idea is to build up a jig as seen in this image

And try to undo it from inside.
Would this work?

I have some left handed drill bits on order. This is my next strategy to get that sucker (lower damper rod retaining screw) out, so I cross my fingers that I do not ruin the female threads in the process.

Anyone out there have any pointers for me? That would be very welcome thanks.

 

drill the head off or use an easy out screw extractor
I apply heat to warm/soften the loctite on bolt

 

I'll second the motion.
Since the head is stripped a easy out will just break.
Drill the head off and pull the inner tube out. The remaining bolt will have plenty of material left to grab to remove. It is a common problem, the head is corroded in the fork tube and stuck. Put a little anti-seze on the bolt head when reassembling, Don't forget the copper sealing washer under the head.

Remember it is always easier to break that bolt loose BEFORE you remove the forks. That way you don't need a fancy rig to hold the fork, the bike does it.

 

Before you drill anything.
Use the next size up of Torx driver. Hammer that into the head of the screw. It won't strip out easily.

 

+1^ heat with torch to soften loc tite thread compound

 

+1 ^. These guys are good.

Gary H.

 

That would work also but it would ruin the torx bit. The bolt is already trashed and needs to be replaced. Drill it and save the tool.

 

A Torx bit will not be ruined by a relatively soft steel bolt (unless it's crap tool to begin with). I've been using this method for 30 years without ruining a bit yet (well not ruining one this way at least; I've ruined them plenty of other ways though).

 

I have done it many times too, I just cringe when I have to take a hammer to a good tool. But it has to be done sometimes. I don't do it if I done have to. I can say there quite a few tools in my box with hammer dings on them.
It would take less time to drill the head off.

 

I will try this out.

 

Also, for leverage, I throw the axle or even just a socket extension in the fork to leverage against.