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Tool Talk Discussion Forum

Broken bolt / stud removal

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Phil Tibbetts

07-27-2006 18:37:11




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I have worked a a machinist for nearly 40 years and have had success in removing broken bolts or studs by first welding a good thick washer onto the end of the stud. The washer hole should be slightly smaller than the stud, especially if the stud is broke off flush. Next weld a nut to the washer. This will work about 75% of the time for me if I get good welding penetration to the stud and washer. I also think the heat generated helps to free up the stud. Wait for the piece to cool before trying to remove the stud. If the piece the stud is broken off in is not too thick around the stud you can reheat it while trying to remove the stud. This works really good in aluminumas it expands faster than steel or iron. Hope this helps someone.

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bill from wisc

07-30-2006 10:04:03




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 Re: Broken bolt / stud removal in reply to Phil Tibbetts, 07-27-2006 18:37:11  
Phil another trick a old machinist showed me when welding a nut or washer on failed, was to heat the broken off bolt or fitting to as hot as you can get it then add plain old bees wax as it cools. First time I saw it I thought the guy was joking with me.As its cooling down the wax gets sucked into the threads It has worked every time for me.I have had alot of fittings that I could turn out by hand once it cooled down. Be sure to use bees wax and not candle wax.I wish I had been showed that 20 years ago.

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doubletough

07-27-2006 20:02:51




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 Re: Broken bolt / stud removal in reply to Phil Tibbetts, 07-27-2006 18:37:11  
can you tell me what size drill to use for rethreading a 5/8 hole?



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Phil Tibbetts

07-28-2006 04:13:25




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 Re: Broken bolt / stud removal in reply to doubletough, 07-27-2006 20:02:51  
17/32 for Coarse....9/16 for fine



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doubletough

07-28-2006 05:19:50




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 Re: Broken bolt / stud removal in reply to Phil Tibbetts, 07-28-2006 04:13:25  
Thanks



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Bob

07-27-2006 20:11:49




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 Re: Broken bolt / stud removal in reply to doubletough, 07-27-2006 20:02:51  
Here's a link I use:



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old

07-27-2006 21:04:53




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 Re: Broken bolt / stud removal in reply to Bob, 07-27-2006 20:11:49  
Bob you forgot he link you use LOL



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Bob

07-27-2006 21:49:31




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 Re: Broken bolt / stud removal in reply to old, 07-27-2006 21:04:53  
The link won't post in the box, so you'll have to "cut and paste".


http://www.engineersedge.com/tap_drill_chart.htm



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