I was trying to get a cam gear cap/bolt thing off a 2000 Volvo S80 2.9l and stripped the torx pattern out of a bolt. I'd guess it's around 1-1/2" in diameter, and this is what it looks like:
I have tried other things like using JB Weld to hold a torx bit in and cutting a slot in the cap and trying to use a hammer and screwdriver to turn it but nothing has worked so far. Besides drilling it out, the only other thing I can think of is welding a nut to it (don't have enough room to fit a normal sized drill and bit in there anyway).
I've only ever tack welded for a job I had and they set everything up for me. I'm not sure what amperage or the kind of sticks I need. I definitely don't want to blow through the cap, or weld it to what's behind it. It needs a strong weld, because it doesn't want to come loose for some reason.
What kind of amperage and sticks needed to weld a nut to a stripped cap/bolt?
Can someone provide me with some direction on how to get this done successfully?