Broken Bolt Extraction
Every once in awhile, a bolt will break off leaving nothing to grab hold of. Getting it out can be frustrating to say the least. It's common for threads to seize if the bolt is made of a different metal than the threads in the hole. Different methods have been developed to extract these stubborn bolts. Here's a method I prefer if conditions allow.
Conditions required:
The surfaces MUST be able to withstand intense heat without being damaged.
Keep any flammable items far away.
Disconnect or remove any electronics that could be damaged by welding.
Supplies needed:
- welding equipment - preferably a MIG welder with gas and solid wire
- scrap steel plate (18 gauge steel is good but thicker is OK)
- a drill bit the same diameter as the bolt you're trying to extract
- a large nut
- hammer
- wrench to fit the nut or an adjustable wrench
Every once in awhile, a bolt will break off leaving nothing to grab hold of. Getting it out can be frustrating to say the least. It's common for threads to seize if the bolt is made of a different metal than the threads in the hole. Different methods have been developed to extract these stubborn bolts. Here's a method I prefer if conditions allow.
Conditions required:
The surfaces MUST be able to withstand intense heat without being damaged.
Keep any flammable items far away.
Disconnect or remove any electronics that could be damaged by welding.
Supplies needed:
- welding equipment - preferably a MIG welder with gas and solid wire
- scrap steel plate (18 gauge steel is good but thicker is OK)
- a drill bit the same diameter as the bolt you're trying to extract
- a large nut
- hammer
- wrench to fit the nut or an adjustable wrench
The following pictures show the steps I used to remove a broken exhaust manifold bolt seized inside an engine head.
1. I knew it was safe to apply intense heat to the engine head and broken bolt.
2. Flammable items were far away.
3. No electronic items were connected that could possibly be damaged.
1. I knew it was safe to apply intense heat to the engine head and broken bolt.
2. Flammable items were far away.
3. No electronic items were connected that could possibly be damaged.