How to Remove a Broken Bolt by Welding
To remove a broken bolt by welding, you can follow these steps:
1.
Find a smaller solid bolt that fits comfortably in the hole left by the broken bolt.
2.
File or grind the sheared off bolt until it is flat and clean.
3.
Mark the center point of the sheared off bolt using a center-punch.
4.
Drill a hole that matches the size of the selected bolt, with a depth of around three to four millimeters.
5.
Use super glue to attach the selected bolt securely in place.
6.
Weld the bolt using the lightest rod that will stick to the shaft, preferably a MIG welder or an arc welder.
7.
Allow the bolt to cool for five to ten minutes.
8.
Use a spanner or adjustable wrench to nudge the bolt back and forth, working it free.
9.
Once the bolt frees up, turn it out to completely remove it.
Please note that welding a nut of the same size over the sheared head is also a common approach to removing broken bolts.
The heat generated by the welding process breaks the molecular bond holding the bolt or screw threads, while the subsequent cooling action helps separate the metals by expanding them at different rates.
Another method involves welding a smaller bolt onto the head of the stud to support a wrench while removing the stud.
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Did You Know?
1. Did you know that welding can be used not only to repair broken bolts but also to remove them? By applying controlled heat through welding, a broken bolt can be easily detached from its surrounding material.
2. When using welding to remove a broken bolt, it is important to note that different types of bolts require different welding techniques. For example, a stainless steel bolt requires a lower heat setting compared to a carbon steel bolt to avoid damaging the surrounding area.
3. One common method to remove a broken bolt by welding involves welding a nut onto the broken bolt. By heating the bolt and melting the surrounding metal, the nut can be effectively fused to the bolt, allowing for easy removal with a wrench.
4. Another lesser-known technique involves welding a small rod onto the top of the broken bolt. Through this method, the rod acts as a handle, allowing for improved grip and leverage when attempting to remove the bolt manually.
5. It is important to exercise caution and precision when using welding to remove a broken bolt. Overheating the surrounding material can lead to irreversible damage and potential structural weaknesses, making it crucial to follow proper welding guidelines and seek professional assistance when necessary.
Find A Smaller Solid Bolt
When dealing with a broken bolt, the first step is to find a smaller solid bolt that will fit snugly into the hole left by the sheared off bolt. This replacement bolt will act as a new anchor for the welding process. It is crucial to choose a bolt that is of high quality and made of a similar material to the original bolt to ensure a successful extraction.
File Or Grind The Sheared Off Bolt
Once you have found the replacement bolt, the next step is to file or grind the sheared off bolt until it is flat and clean. It is important to remove any uneven surfaces or burrs to create a smooth and even base for drilling and welding. This step requires patience and precision to achieve the best results.
Drill A Hole For The Selected Bolt
After preparing the sheared off bolt, mark the center point of the bolt using a center-punch. This mark will serve as a guide for drilling a hole in which the replacement bolt will be placed. Drill the hole at the correct size to ensure a proper fit for the replacement bolt. The depth of the hole should be around three to four millimeters, allowing enough space for the welding process.
Super Glue The Bolt In Place
With the hole drilled, the next step is to super glue the replacement bolt in place. Applying a small amount of super glue around the surface of the bolt will secure it within the hole and prevent any movement during the welding process. The glue acts as a temporary adhesive until the bolt is welded in place.
Weld The Bolt Using The Lightest Rod
Now that the replacement bolt is in position, it is time to weld it. It is recommended to use a MIG welder for this task, but an arc welder can also be used.
Here are the steps to follow:
- Choose the lightest welding rod that will still stick to the shaft of the bolt.
- Carefully weld the bolt, ensuring proper penetration and bonding with the surrounding materials.
Tip: Pay close attention to the welding process to ensure a strong and durable connection.
Remember, welding is a critical step in securing the bolt, so take your time and ensure it is done correctly.
Nudge And Remove The Bolt
After the welding process, it is important to allow the bolt to cool for about five to ten minutes. This cooling period ensures that the metal solidifies and stabilizes. Once cooled, use a spanner or adjustable wrench to nudge the bolt back and forth gently. This movement helps to break any remaining molecular bonds and loosen the bolt. Gradually increase the force until the bolt works free and can be turned out smoothly.
Removing a broken bolt by welding requires careful steps and proper execution. Finding a smaller solid bolt, filing or grinding the sheared off bolt, drilling a hole, and super gluing the replacement bolt are important preparatory steps. Once these steps are completed, welding the bolt using the lightest rod and allowing the bolt to cool before gently nudging and removing it will ensure a successful extraction. Exercise caution and patience throughout the process to achieve the best results.
Frequently Asked Questions
How do you remove a welded bolt?
To remove a welded bolt, first, utilize an oxy-acetylene torch to carefully heat the surrounding area of the weld until it reaches a temperature that weakens the bond. Once the weld is sufficiently heated, apply a moderate amount of pressure with a wrench to break the bond between the bolt and the material it is welded to. After successfully separating the bolt from the weld, use a wire brush or a similar tool to remove any remaining debris or residue. Finally, inspect the threads and clean them thoroughly using a thread chaser or tap to ensure smooth reinstallation or replacement of the bolt.
What welder is best for bolt removal?
When it comes to bolt removal, the choice of welder is crucial. For this particular job, a TIG welder proves to be the ideal tool. With its precise control and ability to produce clean and accurate welds, a TIG welder allows for more careful and efficient removal of the stuck threaded bolt. In addition, selecting a nut or flat washer with a suitable inner diameter can also aid in the bolt removal process. By ensuring a proper fit, the welder can better secure the nut or washer to the bolt, facilitating an easier extraction.
Another option to consider is the use of a spot welder. While primarily used for joining metal sheets, a spot welder can be repurposed for bolt removal in certain cases. By creating a powerful and localized bond between the bolt and a flat washer or nut, a spot welder can help break the stuck bolt free. However, it’s crucial to assess the application and the type of break that occurred to determine if a spot welder is the best option. Above, below, or flush with the cylinder are key factors to consider, as the location of the break may impact the effectiveness of a spot welder.
What are 3 ways to remove a broken bolt?
One alternative method to remove a broken bolt is by using heat. Applying heat to the area around the bolt can cause it to expand, making it easier to loosen and remove. Another option is to use a threaded insert. By drilling out the broken bolt and inserting a threaded insert, you can create new threads and secure it with a bolt or screw. Lastly, you can try using a left-handed drill bit. These drill bits can grip the broken bolt as they rotate, potentially causing it to loosen and come out while drilling.
How do you remove welded metal?
One way to remove welded metal is through thermal techniques, such as oxyacetylene cutting or gouging, arc gouging, plasma cutting, or laser cutting. These methods involve the use of heat to melt and remove the welded metal. Alternatively, mechanical means such as grinding, sawing, machining, and drilling can also be employed to physically remove the weld. Each method offers its own advantages and may be chosen based on factors such as the size and location of the weld, the desired precision, and the available equipment.