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Better way to remove broken bolts

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Brian

10-25-2000 09:25:42




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The BEST way to remove the bolts that are broke is not to drill them at all. I am a machinist and have taken out more broken bolts than I ever wished to admit. In working in a repair shop we had to fix everything and more often than not there were broken bolts. The way to get them out is to weld on the piece just a little bit on the broken piece. Then spray with WD-40 (any thing like that) then strike it with a hammer. If this process is repeated for many times (hot, cold, impact, and penetrating oil) there will be a nub sticking up and most of the time the bolt can be taken out with your fingers or vice grips in extreme cases. I have done this on bolts from 10-32 to ¾ inch bolts and have got every bolt out.

Hope this can help someone out because this works great

good luck Brian ( I dream in red :))

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bill

11-16-2000 12:52:37




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 Re: Better way to remove broken bolts in reply to Brian , 10-25-2000 09:25:42  
Since I started using left handed drill bits I almost forgot that could be a problem.



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Jim

10-26-2000 21:17:56




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 Re: Better way to remove broken bolts in reply to Brian , 10-25-2000 09:25:42  
I take this process one step further. I drill a hole in the broken off bolt. Then I weld the drilled hole shut with a arc welder. This shrinks the bolt and then it comes right out. I even spray it, beat on it, and weld a nut on it.



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John Ne.

10-26-2000 20:54:11




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 Re: Better way to remove broken bolts in reply to Brian , 10-25-2000 09:25:42  
Sounds like some good methods. I am a full time mechanic, time is money, right? don't have time to tap and squirt, just get out the drill. a little heat, pair of new hex jawed ViseGrips. Easy outs, if really desperate. Find drilling usually does it the fastest. But fully realize, not always possible, on vintage iron.



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kimk

10-25-2000 16:48:58




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 Re: Better way to remove broken bolts in reply to Brian , 10-25-2000 09:25:42  
Add my one vote for hot, cold, penetrating oil, and a little gentle rapping. I think the real secret weapon is time/patience. Doesn't even have to be real hot either, propane torch heat will even work if you take the time to let 'er suck up some heat. Once had a broken bolt in an aluminum transfer case. Gave her the treatment twice a day for three or four days, and she all but walked out on her own. I think the heat causes some expansion which loosens the rust and allows the oil to get in there. A little gentle rapping sets up vibrations which further loosen the rust and also vibrates the oil in. (but maybe I just can't resist any chance to use a hammer)

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BlueLight

10-25-2000 16:15:14




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 Re: Better way to remove broken bolts in reply to Brian , 10-25-2000 09:25:42  
I have a 5/8 bolt head that broke off in the
housing of my tractor. It left a 1/2 inch stub
sticking out. Now I'm no expert at welding, but
isn't it risky to apply heat to steel imbedded in grey iron as the expansion rates are different. This is what's keeping me from welding the head of a 5/8in bolt onto it. There is approx 1 inch from the bolt to the edge of the housing. So I risk having a chip broken away rather than a cracked housing I think. Someone told me it was OK for steel in cast
steel but not in iron. I had planned to drill out with 1/2 in bit
then use a stub remover, but if your sure I'll
weld a head on.

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ltf in nc

10-25-2000 17:12:20




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 Re: Re: Better way to remove broken bolts in reply to BlueLight, 10-25-2000 16:15:14  
I use a slightly different approach. I get a heavy large diameter washer that will fit over the broken shank and weld the stub to the washer. Then I weld a nut the washer. This gives protection of the surrounding area in case I make a mislick with the electrode and affords a large area to attach the nut soundly. I have successfully removed broken bolts that others have given up on using this method, even those that are flush with the surface. Let the weld cool so that the material shrinks prior to attempting to remove the broken bolt. Good luck with whatever method you choose. Post your results

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Jon Hagen

10-25-2000 19:46:10




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 Re: Re: Re: Better way to remove broken bolts in reply to ltf in nc, 10-25-2000 17:12:20  
Have used this method many times with good results. just want to add that candle wax will penetrate into a tight rusted joint where penetrating oil will not go. Just touch a candle to the part while still hot enough to make the wax flow and even smoke a little. I learned this trick for removing tight fitting joints like rusted pipe plugs in water jacket drains and oil galleries. Works even better on bolts because they have a looser fit in the threads.

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Robert Hudson

11-01-2000 11:52:57




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 Re: Re: Re: Re: Better way to remove broken bolts in reply to Jon Hagen, 10-25-2000 19:46:10  
I like the hot, cold, oil method myself for the stubborn fastners. But try this for the not so hard ones. Purchase a good set of left hand twist drills (MSC). Carefully center punch the broken bolt or stud and drill through with the left hand drill. Many times as the drill breaks through the bottom of the fastner, the drill will catch and unscrew the right hand fastner. Its almost like magic. We Make drill bushings that can be used to center the drill for fastners that are broken off below the surface. These can also be purchesed at MSC.

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