How To Remove Bolt With Broken Head

Stripped or broken bolts can be a frustrating obstacle for DIYers and professionals alike. Whether it’s a rusted bolt on a car or a stripped screw in a piece of furniture, removing a bolt with a broken head can seem like an impossible task. But fear not! With a bit of patience and ingenuity, you can conquer this challenge and restore your project to its former glory.

The first step is to assess the situation and determine the type of bolt you’re dealing with. Is it a hex bolt, a socket bolt, or something else? Once you know the type of bolt, you can choose the best method for removing it. For example, if it’s a hex bolt, you might be able to use a pair of pliers or a vise grip to loosen it. If it’s a socket bolt, you’ll need to use a socket wrench or a bolt extractor. No matter which method you choose, be sure to take your time and apply even pressure to avoid damaging the bolt or the surrounding area.

In some cases, you may not be able to remove the bolt using the traditional methods described above. In these cases, you may need to resort to more drastic measures, such as drilling out the bolt or using a bolt extractor. Drilling out the bolt is a risky procedure, so it’s only recommended as a last resort. If you’re not confident in your ability to drill out the bolt, it’s best to leave it to a professional. Bolt extractors are specifically designed to remove broken bolts, and they can be very effective. However, they can also be expensive, so it’s important to weigh the cost of the bolt extractor against the cost of having a professional remove the bolt.

Safety First

When working with tools and machinery, safety should always be your top priority. Here are a few essential safety precautions to keep in mind when attempting to remove a bolt with a broken head:

1. Wear appropriate safety gear: This includes safety glasses, gloves, and sturdy shoes to protect your eyes, hands, and feet from any potential hazards.

2. Secure the workpiece: Before starting, ensure that the workpiece is firmly secured in place to prevent it from moving or shifting during the process. This will help you maintain control and minimize the risk of accidents.

3. Use the right tools: Select the appropriate tools for the job, such as a punch, chisel, or extractor. Make sure the tools are in good condition and sharp to avoid any slippage or injury.

4. Work in a well-lit area: Adequate lighting is crucial for clear visibility and precision. Ensure you have sufficient lighting to avoid straining your eyes or missing any details.

5. Be patient and persistent: Removing a broken bolt head can be challenging and time-consuming. Stay patient and persistent throughout the process. Avoid using excessive force or rushing, as this could lead to further damage or injury.

Safety Precaution	Importance
Wear safety gear	Protect eyes, hands, and feet from hazards
Secure the workpiece	Prevent movement and maintain control
Use the right tools	Minimize slippage and injury
Work in a well-lit area	Ensure clear visibility and precision
Be patient and persistent	Avoid further damage or injury

Use a Bolt Extractor

A bolt extractor, also known as an easy-out, is a tool specifically designed to remove broken bolts. It works by gripping the inside of the broken bolt and turning it counterclockwise to extract it. Here are the steps on how to use a bolt extractor:

Step 1: Select the Right Size Extractor

Choose an extractor that is slightly smaller than the diameter of the broken bolt. A too-small extractor will not grip the bolt securely, while a too-large extractor may damage the bolt hole.

Step 2: Drill a Pilot Hole

Using a drill bit that is slightly smaller than the extractor, drill a pilot hole into the center of the broken bolt. The hole should be deep enough to allow the extractor to bite into the bolt.

Step 3: Tap the Extractor into the Bolt

Using a hammer, gently tap the extractor into the pilot hole. The extractor should be seated firmly in the bolt, ensuring a secure grip.

Step 4: Turn the Extractor Counterclockwise

Using a wrench or pliers, turn the extractor counterclockwise to remove the broken bolt. Apply steady pressure and avoid overtightening, as this can damage the extractor or the bolt hole.

Step 5: Remove the Bolt

Once the bolt is loose, remove the extractor and discard the broken bolt. If the bolt does not come out easily, soak it in penetrating oil or heat it with a torch to loosen it.


Benefits of Using a Bolt Extractor:
• Specific tool designed for broken bolt removal
• Grips and turns the broken bolt directly
• Allows for precise extraction without damaging the bolt hole
Limitations of Using a Bolt Extractor:
• Requires drilling a pilot hole, which may not be feasible in all cases
• Can be difficult to use on bolts that are deeply embedded or rusted

Employ a Pipe Wrench

A pipe wrench, also known as a Stillson wrench, is a specialized tool designed to grip and turn cylindrical objects such as pipes. When faced with a broken bolt head, a pipe wrench can provide the necessary leverage to remove it effectively.

Select the Right Pipe Wrench Size

Choosing the appropriate size pipe wrench is crucial. The wrench’s jaws should be wide enough to fit around the bolt’s body without touching the threads. Refer to the table below for recommended wrench sizes based on bolt diameters:

Bolt Diameter	Pipe Wrench Size
1/4 inch	10 inch
3/8 inch	12 inch
1/2 inch	14 inch
5/8 inch	16 inch
3/4 inch	18 inch

Securely Grip the Bolt

Place the pipe wrench’s jaws around the bolt’s body, ensuring the teeth are firmly engaged. Tighten the wrench using a clockwise motion, but be cautious not to apply excessive force.

Apply Leverage

Use the pipe wrench’s handle as a lever to rotate the bolt. Pull down on the handle, applying slow and steady pressure. Avoid jerking or applying sudden force, as this can damage the bolt or the wrench.

Unscrew the Bolt

Continue rotating the bolt counterclockwise using the pipe wrench until it is completely unscrewed. Remove the wrench and check the threads for any damage. If the threads are stripped or damaged, the bolt may need to be replaced.

Create a New Head

If the bolt head is too damaged to grip with pliers or a wrench, you can create a new head using a few simple tools. This method is particularly useful for bolts that are recessed or in a tight spot.

Materials You’ll Need:

Center punch
Hammer
Drill
Drill bit (slightly smaller than the bolt diameter)
Screw extractor

Steps:

Center punch the bolt: Use the center punch and hammer to create a small indentation in the center of the broken bolt head.
Drill a pilot hole: Insert the drill bit into the indentation and drill a small pilot hole. The hole should be slightly smaller than the diameter of the bolt.
Use a screw extractor: Insert the screw extractor into the pilot hole and turn it counterclockwise to extract the broken bolt. The threads on the extractor will bite into the hole and remove the bolt.

Tips:

If the bolt is made of hardened steel, you may need to use a carbide drill bit.
If the screw extractor doesn’t work, you can try using a left-hand drill bit. These drill bits are designed to extract broken bolts by turning in the opposite direction of normal drill bits.
Always wear safety glasses when working with power tools.

Weld a Nut onto the Bolt

Welding a nut onto the broken head of a bolt is a straightforward method that can save you a lot of time and effort. Here’s a detailed guide on how to do it:

Gather your tools: You’ll need a welding machine, a welding rod, a nut that’s slightly larger than the broken bolt head, and a wire brush.
Clean the area: Use the wire brush to remove any dirt, rust, or debris from the exposed bolt shaft and the nut you’ll be welding on.
Position the nut: Place the nut over the broken bolt head and align it in the center. Tack-weld the nut to the bolt shaft in a few spots to hold it in place.
Weld around the nut: Using a circular motion, weld around the circumference of the nut, creating a bead of weld that fuses the nut to the bolt shaft.
Allow to cool: Let the welded joint cool down completely before proceeding.
Grind off the excess weld: Use a grinder to remove any excess weld from the nut and the bolt shaft.
Use a wrench to remove the bolt: Attach a wrench or socket to the welded nut and turn counterclockwise to remove the bolt.

Additional Notes:

Here are some additional tips to ensure successful welding:

Use a welding rod that’s compatible with the material of the bolt and nut.
Wear proper safety gear, including gloves, eye protection, and a welding helmet.
Practice welding on a scrap piece of metal before attempting the actual repair.
If the bolt is severely rusted or damaged, you may need to use a cutting torch to remove the broken head before welding on a nut.

Drill Out the Bolt

If the bolt is too damaged or rusted to be removed using other methods, drilling it out may be the only option. This process requires careful precision and specialized tools.

Step-by-Step Guide to Drilling Out a Bolt

Safety First: Wear appropriate safety gear, including gloves and eye protection.
Lubricate the Bolt: Apply penetrating oil or lubricant to the bolt to ease the drilling process.
Drill a Pilot Hole: Use a small drill bit (1/16" to 1/8") to create a pilot hole in the center of the bolt head.
Increase Drill Bit Size: Gradually increase the drill bit size until the hole is about half the diameter of the bolt.
Drill Out the Remaining Bolt: Use a drill bit slightly smaller than the bolt’s diameter to drill out the remaining portion of the bolt.
Remove the Bolt Fragments: Use a pick or awl to remove the broken bolt fragments from the hole.
Clean the Hole: Thoroughly clean the hole with a wire brush or compressed air to remove any remaining debris.
Check the Threads: Inspect the threads in the hole to ensure they are not damaged.

Expert Tips for Drilling Out a Bolt

Tip	Explanation
Use a cobalt drill bit	Cobalt drill bits are more durable and can withstand the high temperatures generated during drilling.
Start with a small drill bit	Drilling a small pilot hole first helps to center the drill and prevent the bit from wandering.
Apply steady pressure	Avoid applying excessive pressure, as this can cause the drill bit to break.
Lubricate the drill bit	Lubrication reduces friction and prolongs the life of the drill bit.
Remove the drill bit periodically	Periodically remove the drill bit and clean it to prevent it from overheating.

How to Remove a Bolt with a Broken Head

Removing a bolt with a broken head can be a frustrating experience, but it’s not impossible. There are a few different methods that you can try, depending on the situation. Here are a few of the most common methods:

Use a Bolt Extractor

A bolt extractor is a specialized tool that is designed to remove broken bolts. It works by gripping the sides of the bolt and turning it counterclockwise. Bolt extractors come in a variety of sizes, so be sure to choose one that is the right size for the bolt that you need to remove.

Use a Reverse Drill Bit

A reverse drill bit is a type of drill bit that is designed to turn counterclockwise. This can be useful for removing broken bolts, as it will help to loosen the bolt and make it easier to remove.

Use a Hammer and Chisel

If the other methods don’t work, you can try using a hammer and chisel to remove the broken bolt. This method is more difficult and time-consuming, but it can be effective if the bolt is particularly stubborn.