If you’re ever faced with the frustrating task of removing a snapped bolt from a hole, don’t despair. There are several effective methods you can try to extract the broken bolt without damaging the surrounding material. In this article, we’ll guide you through the steps involved in three common techniques: using a bolt extractor, welding a nut onto the snapped bolt, and drilling out the bolt. Whether you’re a seasoned DIYer or a complete novice, these methods will provide you with the knowledge and confidence to tackle this challenging repair.
Before attempting any of these methods, it’s important to assess the situation and gather the necessary tools. Ensure that you have a good understanding of the type of bolt you’re dealing with, as well as the material of the surrounding surface. Different methods may be more suitable depending on these factors. If the bolt is deeply embedded or the surrounding material is delicate, it may be advisable to seek professional assistance. With the right tools and a little patience, you can successfully remove the snapped bolt and restore your equipment or project to its former glory.
Using a Bolt Extractor
A bolt extractor, also known as a screw extractor or easy-out, is a specialized tool designed to remove broken or damaged bolts from a hole. It consists of a tapered, fluted body with a hardened tip and a square or hexagonal drive head. The tapered design allows the extractor to bite into the damaged bolt, while the flutes provide a path for the extracted material to escape.
To use a bolt extractor, follow these steps:
| Step | Description |
|---|---|
| 1 | Select the correct size extractor for the damaged bolt. The extractor should be slightly smaller than the outer diameter of the bolt. |
| 2 | Center the extractor over the damaged bolt and tap it gently into the hole using a hammer. Make sure the extractor is properly aligned and seated in the hole. |
| 3 | Attach a wrench or socket to the drive head of the extractor and turn it counterclockwise to extract the broken bolt. Apply downward pressure to prevent the extractor from slipping. |
| 4 | If the bolt is particularly stubborn, apply penetrating oil or lubricant to the threads and let it soak for a few minutes before attempting to extract it. |
| 5 | Once the bolt is extracted, clean the threads of the hole and apply an anti-seize compound to prevent future seizing. |
Drilling Out the Bolt
Drilling out the bolt is a more invasive method, but it is often the only option if the bolt is badly rusted or damaged. To drill out the bolt, you will need a drill, a set of drill bits, and a center punch.
Make sure to wear safety glasses and gloves before drilling. First, use the center punch to create a small dent in the center of the bolt. This will help to keep the drill bit from wandering. then select a drill bit that is slightly smaller than the diameter of the bolt.
Start drilling slowly and carefully. Apply gentle pressure to the drill and let the bit do the work. Once the bit has penetrated the bolt, increase the speed and continue drilling until the bolt is completely removed.
| Drill Bit Size | Bolt Diameter |
|---|---|
| 1/16 inch | Up to 1/8 inch |
| 3/32 inch | 1/8 inch to 5/32 inch |
| 1/8 inch | 5/32 inch to 3/16 inch |
| 5/32 inch | 3/16 inch to 7/32 inch |
| 3/16 inch | 7/32 inch to 1/4 inch |
If the bolt is particularly stubborn, you may need to use a larger drill bit. However, it is important to use the smallest bit that will do the job, as this will help to prevent damage to the surrounding material.
Using a Left-Handed Drill Bit
Left-handed drill bits are specially designed to extract broken bolts and screws by drilling in reverse. The counterclockwise rotation of the bit loosens the seized bolt, making it easier to remove.
To use a left-handed drill bit, follow these detailed steps:
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Select the correct drill bit: Choose a left-handed drill bit that is slightly smaller in diameter than the broken bolt. The bit should be able to fit into the hole without touching the surrounding material.
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Prepare the work area: Secure the workpiece and ensure a stable drilling environment. Consider using a drill press for added precision and control.
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Drill a pilot hole: Use a regular drill bit to create a small pilot hole in the center of the broken bolt. This pilot hole will guide the left-handed drill bit and prevent it from wandering.
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Switch to a left-handed drill bit: Insert the left-handed drill bit into the drill and set the drill to reverse rotation.
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Drill slowly and carefully: Start drilling at a low speed and gradually increase the speed as needed. Apply light pressure while drilling to avoid overheating the bit.
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Remove the broken bolt: Once the left-handed drill bit has sufficiently loosened the bolt, use pliers or a wrench to extract it from the hole. If the bolt is still stuck, try repeating the process with a larger left-handed drill bit.
| Step | Action |
|---|---|
| 1 | Select the correct drill bit |
| 2 | Prepare the work area |
| 3 | Drill a pilot hole |
| 4 | Switch to a left-handed drill bit |
| 5 | Drill slowly and carefully |
| 6 | Remove the broken bolt |
Reverse Drilling
Reverse drilling involves carefully using a drill bit to extract the snapped bolt. This method is especially effective for bolts that are not deeply embedded in the hole.
Steps:
- Select a drill bit that is slightly smaller than the diameter of the broken bolt.
- Set your drill to the reverse (counterclockwise) rotation.
- Carefully align the drill bit with the center of the snapped bolt.
- Slowly and with steady pressure, drill into the bolt. As you drill, the bolt threads will catch on the drill bit’s teeth and begin to unscrew.
Tips for Successful Reverse Drilling:
| Tips | Benefits |
|---|---|
| Use a sharp drill bit: | A sharp drill bit will bite into the bolt threads more effectively. |
| Lubricate the drill bit: | Lubrication will reduce friction and make the drilling process smoother. |
| Apply steady downward pressure: | Applying consistent pressure will help to bite into the bolt threads and unscrew it. |
| Drill slowly: | Drilling slowly gives the bolt threads time to catch on the drill bit. |
| Reverse the drill as needed: | If the bolt is not coming out easily, reversing the drill can help to loosen it. |
Heating the Bolt
If a bolt is seized or rusted in place, heating it can help to loosen it. This is because heat causes metal to expand, which can break the bond between the bolt and the hole. You can heat the bolt using a blowtorch, a heat gun, or even a lighter. However, it is important to be careful not to overheat the bolt, as this can damage the metal.
To heat the bolt, place the heat source at the base of the bolt and slowly move it up the shaft. Keep the heat source moving so that the bolt heats evenly. Once the bolt is hot, let it cool down for a few minutes before trying to remove it.
| Tool | Advantages | Disadvantages |
|---|---|---|
| Blowtorch | Can heat bolts quickly | Can overheat and damage bolts if not used carefully |
| Heat gun | Can heat bolts evenly | Takes longer to heat bolts than a blowtorch |
| Lighter | Can be used in tight spaces | Takes longer to heat bolts than a blowtorch or heat gun |
Using a Cold Chisel
A cold chisel is a specialized tool designed for cutting and shaping metal. It consists of a hardened steel blade with a chiseled edge and a handle for gripping. To use a cold chisel to remove a snapped bolt from a hole, follow these steps:
1. Safety First
Wear safety glasses and gloves to protect yourself from flying metal chips. Ensure the workpiece is securely clamped to prevent slipping.
2. Position the Chisel
Hold the cold chisel firmly against the snapped bolt, ensuring the blade is perpendicular to the bolt’s surface. Position the chisel tip slightly below the bolt’s fractured edge.
3. Strike the Chisel
Using a hammer, strike the chisel’s handle sharply but carefully. The impact should fracture the snapped bolt and create a small notch.
4. Rotate the Chisel
Rotate the cold chisel slightly and strike it again to create another notch adjacent to the first one. Repeat this process, gradually rotating the chisel and striking around the circumference of the snapped bolt.
5. Break the Bolt
As you continue to notch the bolt, it will gradually weaken. Eventually, it will snap into pieces that can be easily removed from the hole using a pair of pliers or a flathead screwdriver.
6. The Art of Chiseling
Using a cold chisel effectively requires patience and precision. Here are some tips to enhance your technique:
- Use a Sharp Chisel: A dull chisel will not cut effectively and can easily slip.
- Strike at an Angle: Angle the chisel slightly towards the direction you want the bolt to break.
- Avoid Overstriking: Striking the chisel too hard can damage the workpiece or break the chisel itself.
- Lubricate the Chisel: Applying a small amount of oil or cutting fluid to the chisel can reduce friction and improve cutting efficiency.
- Break into Smaller Pieces: If the snapped bolt is particularly large, you may need to break it into smaller pieces before it can be removed.
- Use a Vise: Securing the workpiece in a vise can provide additional stability and prevent it from moving while using the cold chisel.
| Tool | Use |
|---|---|
| Cold Chisel | Fracture and remove snapped bolts from holes |
| Hammer | Strike the chisel to create notches and break the bolt |
| Safety Glasses | Protect eyes from flying metal chips |
| Gloves | Protect hands from sharp edges and heat |
Welding a Nut onto the Bolt
With the aid of a specific welding device known as a nutsert, you can achieve welding a nut onto an object such as a bolt. Here are the steps on how to get a snapped bolt out of a hole using this method:
1. Select the right nutsert
Depending on the size of the bolt, you need to choose the appropriate nutsert. Measure the bolt’s diameter to ensure you get a nutsert that snugly fits it.
2. Drill a hole in the snapped bolt
In the center of the snapped bolt, use a drill bit that’s slightly smaller than the nutsert’s inner diameter to drill a hole. This hole will house the nutsert.
3. Clean the hole
Get rid of any debris or metal shavings from the hole using a tap and die set. This will help create a clean surface for welding.
4. Insert the nutsert
Apply a small amount of anti-seize compound to the nutsert’s threads. Then, carefully insert it into the hole you drilled in the bolt. Ensure that the nutsert is flush with the bolt’s surface.
5. Weld the nutsert to the bolt
Position the nutsert’s welding tip on the bolt. With a short burst, weld the nutsert to the bolt. Allow it to cool.
6. Remove the welding tip
Once the weld is complete, use a pair of pliers to carefully snap off the nutsert’s welding tip.
7. Test the welded nut
Try to remove the snapped bolt by turning the welded nut using a wrench or socket. If the bolt comes out easily, you have successfully removed it using the nutsert welding method.
Using a Pipe Wrench
Pipe wrenches are a good choice for removing snapped bolts that are not too rusty or corroded. Here’s how to use a pipe wrench to remove a snapped bolt:
- Put on safety glasses and gloves.
- Lock the pipe wrench’s jaws onto the broken bolt. The jaws should be as close to the break as possible.
- Turn the pipe wrench counterclockwise to loosen the bolt.
- If the bolt is too tight to loosen by hand, you can use a cheater bar or a hammer to help you turn the wrench.
- Once the bolt is loose, remove it from the hole.
Here are some tips for using a pipe wrench to remove a snapped bolt:
- Use the correct size pipe wrench for the bolt. A pipe wrench that is too small will not grip the bolt securely, and a pipe wrench that is too large can damage the bolt.
- Do not overtighten the pipe wrench. Overtightening the pipe wrench can damage the bolt or the wrench.
- Be patient. Removing a snapped bolt can be time-consuming.
| Pros | Cons |
|---|---|
| Good for removing rusty or corroded bolts | Can damage the bolt or the wrench if overtightened |
| Can be used in tight spaces | Can be difficult to use on bolts that are not close to the surface |
Removing the Bolt with a Die Grinder
If the center hole is small enough, you can use a die grinder to remove the broken bolt. This method is ideal for bolts that are rusted or damaged and cannot be easily unscrewed. Here are the steps to follow:
Step 1: Gather Your Tools
You will need a die grinder, carbide burr cutter, safety glasses, dust mask, and a shop vacuum.
Step 2: Prepare the Work Area
Wear safety glasses and a dust mask. Set up the broken bolt in a secure position using a vise or clamps.
Step 3: Cut a Slot in the Bolt
Hold the die grinder perpendicular to the bolt and carefully cut a straight slot into the bolt head. The slot should be wide enough to accommodate the carbide burr.
Step 4: Use the Carbide Burr
Install the carbide burr into the die grinder. Position the burr at one end of the slot and slowly grind away the material around the bolt. Work carefully to avoid damaging the surrounding area.
Step 5: Continue Grinding
Continue grinding around the bolt, following the slot. As you remove more material, the bolt should start to loosen. Keep grinding until the bolt is completely freed from the hole.
Step 6: Clean Up
Once the bolt is removed, clean up the area thoroughly with the shop vacuum to remove any debris or metal shavings.
**Tips:**
- Use a sharp carbide burr to cut through the metal efficiently.
- Grind in short bursts to avoid overheating the metal.
- Be patient and take your time to ensure a clean and precise cut.
How to Get a Snapped Bolt Out of a Hole
A snapped bolt is a common problem that can be frustrating to deal with. If you’re not careful, you can easily damage the hole or the surrounding area. However, there are a few simple steps you can follow to remove a snapped bolt without causing any damage.
1. Gather your tools. You will need the following tools: a drill, a drill bit, a punch, and a hammer.
2. Drill a hole in the center of the snapped bolt. The hole should be as small as possible, but large enough to accommodate the punch.
3. Insert the punch into the hole and tap it with the hammer until the snapped bolt breaks loose.
People Also Ask:
What if the snapped bolt is too close to the edge of the hole?
If the snapped bolt is too close to the edge of the hole, you may not be able to drill a hole in the center. In this case, you can try drilling a hole at an angle. Be careful not to drill into the side of the hole, as this could damage the threads.
What if the snapped bolt is made of a hard metal?
If the snapped bolt is made of a hard metal, you may need to use a carbide drill bit. Carbide drill bits are more durable than standard drill bits and can cut through hard metals more easily.
