How to Remove a Broken Bolt

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A bolt is a piece of hardware that is often used to secure two or more pieces of timber together. Unfortunately, it is possible for a bolt to break during construction. While this is infrequent, it is more likely to occur in untrained or hasty work. Learning how to remove a damaged bolt is necessary for finishing construction or home improvement jobs.

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Using an Extracting Kit

1. Punch the shattered bolt as near to the center as you can. Mark the center of the broken bolt with a center punch and a hammer. This will allow you to drill as near to the center of the bolt as possible, reducing the danger of harming the threads of the fractured bolt.

2. With the left-handed drill bit, drill a pilot hole into the middle of the fractured bolt. Because a left-handed drill bit is threaded in the other way, the reverse setting on your drill will be what drives the bit in. You should use a left-handed bit because it will twist in the opposite direction as the damaged bolt, preventing it from being pushed in any tighter.

  • If you’re fortunate, the left-handed bit will snag and unscrew the bolt enough for you to hold it with a set of vice grips or channel locks and finish removing it.
  • Make sure you use the correct size drill bit. The extraction kit’s bits should come with a chart that tells you what size to use depending on the size of the bolt you need to remove. Using too large a bit risks injuring the bolt’s threads, while using too tiny a bit necessitates a smaller, weaker extractor with a larger danger of breaking off during the operation.
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3. Insert the appropriate-size extraction bit into the drill hole you made. The extracting bit will have a tapered, left-handed bit at one end and either a hex head or a T-handle head at the other, depending on the kind of extracting kit you ordered. Because the extractor is also a left-handed bit, it will work its way through the fractured bolt counterclockwise.
Because the extractor is tapered, tap it into place with a hammer first before moving to a socket or T-handle.

4. Take out the fractured bolt. As you tighten the extractor more, the tapered end will catch, and the torque will work to release the bolt until the extracting bit is snug.

  • Turn the extraction tool counterclockwise until the broken bolt is entirely removed from the surface it was lodged in.
  • Take your time throughout this operation to avoid causing significant damage to either the bolt or the object from which it is being removed. You should also handle the extractor with care since it is made of hardened steel, and a broken off extractor will be considerably more difficult to drill out.

5. Metal filings should be removed. Small quantities of metal fillings are likely to have fallen off the bolt during the removal operation. If you want to repair the damaged bolt, you must first remove all of the fillings and shavings. This is most simply accomplished with a magnet or pressurized air.

Using a Welding Technique

1. Punch the shattered bolt as near to the center as you can. To mark the center of the bolt, use a hammer and a center punch, just like you would with the extractor.

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2. Drill a hole in the middle of the bolt. Drill it out using a bit that is about one-quarter the diameter of the bolt.
This technique of extraction is normally reserved for bolts that are too rusted to be removed with an extractor, so you don’t have to worry about tightening the bolt when drilling it out with a right-handed bit, but using a left-handed bit can’t harm.

3. Attach a hex nut to the bolt. Tighten a hex nut onto any remaining threads on the bolt. Attach the nut tightly, but back it off about a half-turn so that it isn’t fully flush with the surface into which the bolt is buried.

4. Weld the bolt and nut together. This is a rapid weld, but it should not be your first effort at welding. If necessary, have an experienced buddy finish the weld, or practice on something else first using the knowledge available under Weld.
Be extra cautious if the fractured bolt is lodged in a surface that will melt to the steel bolt or nut. As a result, this approach works best against a surface that does not readily weld to steel, such as aluminum.

5. Take out the bolt. After the weld has cooled, the hex nut has been welded into position as the replacement head of the bolt and may most likely be removed with a socket or a wrench.

  • The weld is robust, but it is not indestructible. For heavily corroded bolts, the nut may need to be welded back in place many times.
  • To begin breaking the corrosion bonds, carefully move the bolt back and forth. Once it begins to loosen, continue working in both directions, preferably counterclockwise, until you can begin removing it completely.
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How do you remove a broken rusted bolt without heat?

How do you remove a corroded bolt that has no head? Using a hammer to apply force to a rusty fastener is another option. Strike the fastener’s head with a hammer while wearing an eye protection shield. As you strike, use a screwdriver to try to extract the fastener.

What type of drill bit will drill through hardened steel?

piece of cobalt
Purchase a cobalt bit developed particularly for drilling into steel from a hardware or home improvement shop. A cobalt bit is a high-speed steel (HSS) that contains more cobalt and is powerful enough to cut through hardened steel.

Can you hacksaw through a bolt?

A hacksaw is preferred, particularly for bigger bolts. After the bolt has been cut, use a fine or medium metal file to carefully file any extra metal away from the rim of the cut. You’re just concerned in removing any bigger fragments. Now unscrew the bolt’s outermost nut.

Will a Dremel cut a bolt?

Cut rusted bolts with your Dremel. A Dremel is a handy hand-held tool with a variety of attachments for carving, cleaning, and cutting through wood and metal. It may be used safely to cut through rusty fasteners that would otherwise be impossible to remove.

What tool is used to cut bolts?

Cutter for Bolts
Bolt cutters are tools used to remove screws, bolts, and other metal fasteners. Because these fittings are often large in diameter, bolt cutters exist in a range of sizes with lengthy handles and lever mechanisms.

Does heating metal make it easier to drill?

The quicker a bit rotates, the hotter it becomes. And heat soon dulls pieces. In general, it’s best to drill through metal at the slowest feasible speed using a metal drill bit.

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