How to remove a broken bolt without a drill. 2 Methods

[bri2203]

Do I need a disclaimer? or it is assumed that I am not responsible for your actions?
This How to will cover two methods to remove a broken bolt.

Method 1
(This is a good method if you think the bolt might break, so it can be removed in one piece. It also applies to studs, as well at fitting as this how-to covers.)

Tools Needed
-Gloves
-Safety glasses
-Torch
-Vice Grips/socket/wrench

1. Secure the item in a fixed position. For this item I clamped it in the vice and as you can see someone already TRIED to remove this fitting as it is no longer a hexagon.


2. With your gloves and eye protection on, fire up the troch and get the area around the stuck piece glowing red/orange. Be sure to distribute the heat equally around the stuck portion. IMO the heat breaks the corrision bond more so than the metal expanding.


3. Quickly turn off the torch and grab your vice grips. Grab the fitting/bolt and it should break loose. Somtimes it requires wiggling it back in forth but it will break free.


4. The finished product.



Method 2

Tools Needed
1. Gloves
2. Safety glasses
3. Welder
4. Nuts and washers
5. Open ended wrenchs/sockets
6. Wire bush/ sand paper

This method works well for bolts that are broken off flush in the part.


1. Clean off the area off to get rid of any rust/impurities with a wire wheel, abbrasive disc, or sandpaper.

2. Find a washer that fit snugly around the size of the broken bolt. (Some people skip this step but I feel a washer gets better penetration to tbe bolt vs welding through the center of the nut which is not the easiest)

3. Weld the washer to broken bolt


4. Place a nut on top of washer.


5. Weld the nut to the washer. I like to weld the nut internaly as well as externaly where it contacts the washer.(kinda hard on this example)


6. Let the nut cool down for 30 seconds, and loosed the nut with a socket/wench and this should be your final product.

[meissen]

Awesome writeup, Bri - thanks for taking the time and showing the pics!

[Fbomb]

I've also heard you can use an air chisel to get at the bolt at an angle and start to drive it out. Probably only for larger bolts though.

[bri2203]

Awesome writeup, Bri - thanks for taking the time and showing the pics!

No Problem, I Hope you learned something

I've also heard you can use an air chisel to get at the bolt at an angle and start to drive it out. Probably only for larger bolts though.

This method works well to remove suspension bushings sleves but I have never heard of people doing it on a bolt that is threaded into something. But I am sure it would work as some people tap the bolt with a hammer that helps break a bolt free as well.

[1slo_camaro]

hahahah i remember my stock manifolds i said to hell with it and just trashed them. but my buddies we used the torch. and countless times used a chiself, punch and a hammer and tapped it out slowly but surely lol

[2002Z4CSS]

That procedure works!

[WMCCjames]

Nice write-up. I use "method 2" quite often and it works everytime. However, F-Bomb brings up a good altenative to those who may not have access to a welder or torch...I have used that method several times myself with somewhat good success.....it tends not to work so well on rusty bolts though.

[MP81]

Very cool, Brian.

[ezcruisn71]

Very nice writeup. On method one if you use some "bees wax" after you heat it with the torch it helps remove rusty bolts. We use that at work on exhaust manifolds and it works great.

[meissen]

No Problem, I Hope you learned something

Sho' did - I learned I need to learn how to weld.

[ezcruisn71]

Sho' did - I learned I need to learn how to weld.

Anybody can weld with a mig welder.

[DETROITMUSCLE]

Me too Brian, I have wanted to learn for a while but the time to do so is lacking.

[Gottork]

I learned both methods at work, cause they REFUSED to help me, so I had to try weird shit and see what worked..

its really hard on semi lugnutz though,lol..

[ITSSLOW]

Nice little write up. I frequently use both methods. My welder has really became my friend with restoring cars. I probably used method 2 a dozen times tearing apart my dad's Mustang.

[Darren]

Very cool thanks for the post! Sticky?