Workshop Tips & Tricks #2 – How to remove a broken bolt or stud using a welder

Need to remove a broken bolt or stud?  Most of us would have come across this situation at one stage or another, weekend maintenance at home or in the work environment.  Not all of us have an “extractor tool kit” handy, (which is fine to use for smaller diameter bolts/studs, and dependent upon how seized the bolt/stud is) so if you have a welder handy, we’ll take you through the process of how to remove a broken bolt or stud using a welder!

How to remove a broken bolt - Broken Bolt

Broken Bolt

Prepare the surface

Ensure that the surface around the broken bolt is clean. Remove any excess surface rust, scale, grease etc. Use a grinding wheel to remove as much as possible.

How to remove a broken bolt - Prepared Surface

Prepared Surface

Ready for welding

Have a look around for a nut that is roughly one size smaller than the broken bolt/stud. This will avoid possibility of accidently welding the bolt/stud to the threaded hole.  Keep in mind that the nut will need enough inner surface to be filled with weld.

Weld nut to exposed bolt/stud surface

Simply weld the inner surface of the nut by progressively filling the nut cavity until full.  Once again, be careful not to weld the nut surface to the existing material.  Allow to cool.

How to remove a broken bolt- Welded Nut

Welded Nut


All that you should need now is the applicable size spanner to suit. Remove broken stud/bolt.  There may be times whereby the bolt/stud is seized tight, try using an aerosol penetrative oil product such as Chemtools R10 Bolt Ezy Penetrating Oil (available from IBS).  Allow product to work in, leave for a while, & try again with the spanner.

How to remove a broken bolt - Removal


How to remove a broken bolt - Removal


Another easy process to save a lot of unnecessary headaches!

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