How to Remove a Broken Bolt

Bolts are metal parts commonly used to connect two or more objects together. Unfortunately, during construction, bolts can break. Although this rarely happens, inexperienced people or hasty work can cause bolts to break. For construction or home improvement projects, the skill of removing broken bolts is essential.

Table of Contents

Use a bolt remover kit

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Place the punch in the center of the bolt body, as close to the center as possible. Use a hammer to drive the punch to mark the center of the bolt. This step will help you drill into the bolt center most accurately, reducing the risk of damaging the bolt thread. ^{[1] X Research Source}

Drill a guide hole into the center of the bolt with a counter drill bit. The counter drill has a reverse thread, so the reverse run on the drill will actually drive the drill in. You need to use the drill in the opposite direction because it will create torque in the direction of opening the bolt, to prevent the bolt from being tightened. ^{[2] X Research Source}

If you’re lucky, the counter-drill bit can eat into the bolt and unscrew the bolt yourself a bit, you’ll use pliers to remove it completely.
Remember to use the correct size drill bit. The drill bits in the kit have instructions so you know what size to use based on the size of the bolt to be removed. Using a drill that is too large can damage the thread of the bolt, and using a drill that is too small will require a smaller and weaker retractor that may break during disassembly.

Place the appropriate sized drawstring in the hole you just drilled. Depending on the type of bolting kit, the drawstring will have one end a counter-drill with a bevel, and the other end a hexagon or T-handle attachment. Because the retractor is also a drill. counterclockwise so it will enter the bolt in a counterclockwise motion. ^{[3] X Research Sources}

Since the retractor is beveled, you’ll initially hammer it into the bolt, before attaching it to the T-handle or drill.

Remove the broken bolt. While you are drilling the retract into the bolt, torque is generated and will unscrew the bolt once the retractor is firmly engaged in the bolt.

Continue to rotate the retractor counterclockwise until the broken bolt is completely removed from the surface of the object.
Work slowly to prevent damage to the bolt or bolted object. You should also work gently with the retractor as it is made of hardened steel, so a broken retractor will be even more difficult to remove than a bolt.

Metal mite cleaning. During the bolt removal process, some metal chips will be removed from the bolt. If you are going to replace the bolt with a new one, clean the metal chips in the hole. You can use a magnet or compressed air to suck out metal chips.

Using welding technique

Place the punch in the center of the bolt body, as close to the center as possible. Just like using a bolt remover, you will use a hammer and punch to mark the center of the bolt.

Drill a hole in the center of the bolt. Use a drill about a quarter of the bolt diameter and drill a guide hole. ^{[4] X Research Sources}

This method is usually for bolts that are so heavily rusted that the unscrewing tool can’t be used, so you don’t have to worry about the bolt getting tightened by using a forward drill, but using a counter drill is fine. than.

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Screw the hex nut onto the bolt. You will screw the nut into the bolt, regardless of how much thread is left on the bolt. You should tighten the nut, but turn it open half a turn so it doesn’t completely touch the bolt surface. ^{[5] X Research Sources}

Solder the nut to the bolt. This is just a dot weld, but still requires a bit of soldering experience. If you have never soldered before, you should ask someone with experience to make welds, or practice welding on other objects first with the instructions online.

Be especially careful if the bolting surface can be melted into the bolt or nut. For this reason, this method is best suited for aluminum surfaces because aluminum does not readily adhere to steel.

Remove the broken bolt. After the weld has cooled, the base nut has been welded in place like the new head of the bolt, so it can be opened with a pipe wrench or wrench.

The weld is quite stiff but can still break. For heavily rusted bolts, you may need to weld nuts in multiple locations.
To break the bond caused by corrosion, you should start back and forth very slowly at first. Once the bolt is loosened, keep twisting in both directions but twisting more counterclockwise, you will eventually get the bolt out. ^{[6] X Research Sources}

Warning

Work slowly with the retractor and do not use too much force. If you break the drawstring in the bolt, you will need a drill bit harder than the steel of the retractor to get it out.
Take the necessary protective measures when using welding, including jackets, masks, gloves, long pants, and boots.
Wear safety goggles when drilling as metal chips can get into your eyes.

Things you need

Drill
Reverse drill bit
Withdrawn nose
Handle with the letter T
Pliers
Magnet
Hammer
Punch nose
Pneumatic
Hexagon nut
Welder
Protective mask when welding
Welding protective vest
Glove
Safety glasses

Steps

Use a bolt remover kit

Using welding technique

Warning

Things you need

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