Removing a broken bolt using a welder
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- Опубліковано 16 лис 2011
- Removing a broken or sheared bolt or stud is never easy, but if you have a welder (a mig welder is preferred) you can sometimes weld a nut to the end of the broken bolt. The heat generated by the welding process often helps to loosen the bolt and makes removal of the bolt can be achieved very easily with a spanner.
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Put a washer below the nut first to raise the nut up from the surface giving extra clearance from the surface and also protection from weld running out on to the work surface fusing the stud to piece your trying to remove it from defeating the whole object as the molten metal will always take the path of least resistance so if theres any gaps it will find them. Then put the nut on top of the washer then push the welding rod straight down vertically into the centre of the nut onto the broken stud so your penetrating into the top of the stud and then just fill the centre of the washer & nut with weld. Then let it cool right down before trying to undo it as when it cools it will retract /shrink making it even easier to remove. You can also drill down the centre of the broken stud as well to get even better penetration on really stubborn studs and repeat the process as above.
Thank you for another great video. I do hope you keep making videos and welding would be a great topic.
very good idea... I'm going to try it on my car's cooling fan hood. one bolt broke off and fan is now rattling. thanks for sharing a good tip...
Your vids are surprisingly enjoying to watch! Subbed!
Thanks i must get one,look forward to your welding videos.
Great idea. I was planning on using a welder to get a bolt out, but I couldn't think of what to weld onto it.
Very nicely done.
Great tip once again!
Great advice
Ive be using this metod for many years but i start making some points and clean the slag, one in the top of each other until i have grown a stack of weald at least the heigh of my nut then i make a final weld, that help to prvent th nut of moving and the temperature helps removing the bolt
sir, you are a genius! wish you were my neighbor...
THIS IS AN AWESOME IDEA!!
its cool that u can kinda c thought the nut while he's welding
I need you to come to my house and help me with this old truck I have and a couple of bolts. I wonder if paying your airfare to and from and all your expenses is cost effective? LOL.
Great video man! Thanks!
Galvanic corrosion! I knew there was a technical name for it!!
Thanks
Dissimilar metals can suffer from galvanic corrosion - essentially they set up a small battery with the moisture present and one of the metals gets dissolved and deposited on the other. In the olden days they used to use zinc nails to fasten the copper sheets onto warships - I think this is how they figured it out initially. The saltwater and dissimilar metals caused the hole to increase in size until the plates fell off.
I will try this method on the battery terminals.
I welded a nut to my cars oil sump plug since (hex socket hole rounded off) it was made of steel and my sump was made of aluminium and they had corroded together (technical name for this escapes me!) I had to weld upside down while under the car, not fun but it worked. Holding the nut in place with a piece of wood just cut to the right length. mig welder was ideal since it allowed for small precise tacks
Interesting technique. I bet this has saved your hide a few times. I will give this a try with my everlast welder.
Absolutely, we use this technique a lot on site when lifting steel floor plates.
Thanks for the comment
Well, sometimes you may require special welding rods (to remove very tight bolt) like CGS 680 as bolts are made from alloy steel. Another trick to remove broken bolt deep inside is to use MS pipe piece of smaller diameter than that of tapped hole & weld it from inside to the broken bolt. Bigger size bolts like M16 can be easily removed by this.
Thanks for the comment 👍
In my opinion bolt extractors might be a worse off option. They break so easily, which causes a bigger problem. Use a chiesel and try to hit the bolt in the direction you disassemble it. In theory when the head is off the bolt its not pulling on the threads, which means it should be easy to remove. Try this before you do something more drastic. If you spray in some wd40, and hit the bolt with a hammer and chiesel it might be removable.
I need help mate! I broke one of my 8mm screws in one of my oil filter holes. But it broke off a cm in the hole. What should I do?
I used my drill by cramping the chuck on the exposed broken bolt. If it can be held by a pliers its as easy as setting the drill to reverse after you tighten the chuck on the broken bolt.
Thanks for the comment 👍
which grade welding electrode u using for this ?
is this video about removing a bolt with a broken easy out in it?
How does the weld work,does it just melt the two together?
will you be doing a welding video soon,thanks.
using this method is difficult to do because a lot of times you hit the rod on the nut and don't get a good weld;I cover the rod with shrink tube to help as my vision and steadiness have gotten worse over the years.I like the superglue cheat!great advantage
Weld the washer firs and than weld bolt on washer
May I ask what thus purpose of washer is mate seen videos of that method but trying to figure why it's better that way
@Ultimate Handyman can this technique also remove a wheel stud that has been overtorqued? my wheel nut has split off from its ball seat base when i used a breaker bar to remove it and now all thats left is the wheel stud & ball seat portion of wheel nut
It's worth a try, but a mate of mine is a coded welder and he once tried to do this with a security stud and it did not work.
I have drilled wheel bolts in the past- which might be another option, if welding the nut fails-
ua-cam.com/video/8Rm9fBXIzPg/v-deo.html
Thanks for the comment 👍
I experimented with stick welding a nut on an M12 bolt. I used a 7014 rod and small cheap DC welder. For my first attempt I fed the rod in as evenly as I could until the nut was filled and glowing red. That one broke at a mere 15 ft-lb. It was totally contaminated with slag. For my second attempt I did small individual welds and cleaned it out with a carbide burr before welding again. The nut was full after five individual welds. That one broke free at 80 ft-lb. Obviously a big improvement, bit it still had some slag contamination and could be stronger. The second technique is promising. I'd use it if I had no choice, but after all that I'm going to drill out the bolt because I don't think can weld it a accurately enough on the car to get a reliable result and the bolt is severely seized in there.
I normally use 6013 rods. Hopefully in your scenario, the heat might help to loosen the bolt.
Sometimes I have had to have a few attempts, before it's welded enough to extract the bolt.
Best of luck with it 👍
How do you remove the nut from the broken bolt after it has been welded?
You don't, it gets thrown in the scrap bin.
Thanks for the comment 👍
theirs nothing bad about arc welders vs mig really. some may call it old fashioned, but its built many bridges, and similar things where sheiding gas is not practical or gets blown away. theirs a rather nice feeling once you take a 7018 rod to something its going to stay put with minimal hassle.
+twilson1118 Absolutely.Thanks for the comment
+twilson1118 Especially when all you have is a good stick welder.
I love my MIG welder, but one of my favorite things about stick is that you can weld without removing the plating on most materials (with proper ventilation and respiratory ppe of course).
I've got admit that although my everlast mig welder can stick weld too I probably don't take advantage of it as much as I should. Stick welding can often be the best process to use in many circumstances
Thanks for the comment ;-)
I have a question I have a flex weld machine that I bought from Harbor Freight. Will it remove broken bolts from an exhaust manifold.
You can use virtually any kind of welder, a mig welder is best as there is no slag trapped in the weld.
Where do I attach the ground clamp to if I wanted to do this to get sheared and rusted roof rack bolts out of land cruiser roof gutter?
Best to check with a mechanic, but I believe you disconnect the battery completely from the vehicle, then attach the ground clamp to any earthing point on the vehicle.
I've not done any welding on a vehicle for decades, so best to check with a mechanic 👍
Can I do this with a Flux welder or will I have issues?
You can try this with any welder.
Thanks for the comment 👍
👍
Really struggling to weld a nut to a 6mm stud, it welds on but when I get the wrench on it just comes apart
It's really difficult with M6 studs, sometimes you have to drill the damn things out!
Thanks for the comment 👍
@@ultimatehandyman m10 easier?
me and my dad tried this today on my car it has 3 busted off studs in the exhaust manifold it didn't work very well.
maybe doesn't work very well unless the bolt is sitting on a surface and not being held sideways.
Exhaust manifold studs are a real nightmare to get out, because they have been through so many heating/cooling cycles. Sometimes drilling them out is the only option.
Thanks for the comment 👍
@@ultimatehandyman yeah my dad said that would just result in destroying the head.
The tap I broke is 6mm , is it possible to remove by this
6mm is possible, but you need a small electrode, or even better a MIG welder.
Thanks for the comment 👍
What amperage do you use to weld the nut?
If you use a 1.6mm electrode, I would use about 80 amps
If the bolt 6mm can extract it with stick welding
It is very difficult with small bolts like that, but if you can mig weld or tig weld a nut on the end it might work.
Thanks for the comment
Excellent i have learned something new today.
Its a good day!
>;o)
how long do you have to let it cool
I'd give it 20 minutes 👍
Which electrode did you use?
I normally use 6013 electrodes. Can't remember the diameter, could have been 2mm or 2.5mm
yeah but my problem is 4 anti theft locking wheel nuts. where do i put the earth and how do i clean the locking nut without destroying my alloys
Forget using this method, my mate is a coded welder and had the same problem. He welded a nut on at my house and it sheared right off and did not work. It took him days to remove them and he tried all sorts. He eventually managed it by smashing off the revolving sleeve using a socket and club hammer. He then knocked on a special socket made for this purpose ( I think they are called stud removal sockets)
they are in deep holes in the alloys i cant get to the sleeve. im going to have to find the propper socket. i know of a socket that has lots of pins insde it but i cant find any
Derek Waddell
Were these tightened by an impact wrench at a garage?
If they were I'd go back and ask them to remove them!
Will a 110 mig welder work I wonder
Yes, of course.
A mig is perfect for doing this 👍
will a flux core welder do this job?
Yes, but you need to have the amps high to generate the heat.
Ultimate Handyman cool i hope get to do a few practice welds this weekend with my 125 amp flux core.
Hi mate what ampage did you use ? I'm onto this now x 5 studs ggrr cheers good video
I think I used about 80-100 amps
Thanks for the comment 👍
@@ultimatehandyman ah ok maybe that's my problem onoy gone up to about 60 ish I'll up the anti cheers mate its an Inverter so hopefully won't blow no fuses (240volt plus 13 amp) thanks again
No, No, No, Weld a flat washer to the broken stud and then weld the nut to the washer. If it is really stuck, also weld the nut hole.
guess youve never broken one.
What electrode will create the strongest weld?
I normally use a 6013
Not sure which electrode will give the strongest weld though!
@@ultimatehandyman I just gave it a go with a 7018. Should give a stronger weld, but my nut was M10. A bit small for stick welding.
Thanks for sharing. I just bought a 90 amp flux core welder 110vAC. Would this welder be able to do this?
Thanks.
ravengsxr simply no.
Bolton accent?
It's not cheating if it works.
👍
ezy out seams much ezyer to me
這是浪費螺帽的演出。
An arc welder? Was this filmed in 1910 ? How did the not brake off in the first place ?
Arc welding? Hey guess what your “mig” gun uses to weld with???? Yup an arc. If you plug it in then it’s arc welding. Try cracking a book written after 1956 you’ll be amazed what you can accomplish.
SMAW= Shielded metal ark welding (often known as ark welding)
MIG- metal inert gas
TIG - Tungsten inert gas
You are welcome ;-)
Ok now go get a modern book. Almost no one mig welds anymore. It’s called Gas Metal Arc Welding because most is done with reactive gas, or a mix of reactive and inert ex 75/25.
Tig is an incorrect term also. Inert being the problem word. A lot of “tig”. Is done with reactive gasses so tig is incorrect.
Smaw
Gmaw
Gtaw
Fcaw
They all end in arc welding. So when you said your arc welding you didn’t say much besides hey I’m weldin it
Hey mister! What do I do if my bolt was sheared and i drilled into it using a bolt extractor pig's penis and most of the bolt is broken? how do I avoid weling to the threads of the material and not just the bolt? fcaw.
You can drill out a broken tap- ua-cam.com/video/7JCfEMrCjhc/v-deo.html&t
But if you go down the welding route, try using a smaller diameter nut- that way you are less likely to weld to the component itself.
Thanks for the comment 👍
2:13 haaaaa cheater!