When a broken bolt becomes rusted, it means rust has formed on its threads. Removing a rusted broken bolt largely depends on how much it is broken and how much it is stuck. There are many approaches that can be used to remove broken bolts. The best way is to start with the most simple method, and then work your way up.
- Skill level:
- Moderately Challenging
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Things you need
- Vice grips
- Propane torch
- Penetrating oil
- Wire welder
- Power drill
- Dental pick
- Bolt extractor
Clamp vice grips on the shaft of the bolt.
Turn the bolt with the vice grips until it comes out.
Try turning it both ways if bolt is still stuck. Sometimes the back-and-forth action will help loosen the shaft of the rusted broken bolt.
Use Vice Grips
Use a propane torch to heat the shaft of the bolt. A minute is considered the normal time to heat an average-size bolt. .
Allow bolt to cool to the point where it can be touched with a finger.
Apply penetrating oil around the bolt. Let oil soak in for at least an hour. The longer it soaks, the better.
Tap the bolt with a hammer, or chisel, to help loosen it. This will also allow the oil to further seep in.
Place vice grips on the shaft, and remove the bolt.
Heat the Bolt
Weld the washer to the bolt with a wire welder. Welding the washer also helps transfer heat to the bolt.
Weld a nut to the washer. Make sure the nut is the same size of the head of the bolt, or larger. Weld to the outside parts of the nut.
Place wrench on nut, and remove the bolt.
Weld a Washer
File the shaft of the bolt until it is flat.
Drill into the shaft of the bolt with the smallest bit available. It's possible the drill bit will bind to the bolt, and unscrew the shaft.
Drill again with a bigger bit. Continue drilling with a bigger bit each time until only remnants remain of the shaft.
Remove remnants of shaft with a small item, such as a dental pick.
Drill the Bolt
Drill a hole into the bolt. Start with the smallest bit possible. Make sure hole is centred into the shaft of the bolt.
Hammer the bit of the bolt into the bolt extractor until it is wedged in the shaft.
Pull bolt out by turning the bolt extractor counterclockwise.
If bolt is still stuck, hammer the bit and try pulling out the bolt again.
Use a Bolt Extractor
Tips and warnings
- Be prepared to give penetrating oils plenty of time to work.
- Be careful not to overheat the bolt when using a propane torch.
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