Removing broken bolts

[bm1]

If you've ever built anything, you have most certainly broken a bolt off. So, you get out the drill, drill a crooked hole in the broken bolt, put in an EZ-Out and break it off too. Most of the time, they break off below the surface so you can't even get the trusty Vise-Grips on it. Here's a great way to get them out.
Take a piece if flat bar stock(steel) about 4-6" long. Something about an 1/8th" thick. On one end about a 1/2" from the end, drill a hole just a little smaller than the bolt size and countersink the hole. Lay this piece of steel over the broken bolt countersink side up, and weld it to the bolt. The heat will loosen the bolt and the steel acts as a handel to turn it out with. Pretty easy eh? Good luck

[Prowrench22]

Sounds like another idea for my bag of tricks.

Just to add when using an EZ out make sure you drill the whole way through the broken bolt this will usually shrink the broken bolt some what and when heating with a torch you have a smaller mass to heat and you get a even heat across the broken bolt. :hot:

[dtb69]

:wave: just a thought ,if the handle you weld to bolt is too long,or bolt in tight spot . try welding a bigger nut on broken bolt .then use a socket to get it out , it works good i have done this before, just my to cents , happy holidays to all, :cheers:

[Guy]

For stripped Phillips screws, we used to use a small saw or chisel to turn it into a slotted head type. Then use the "Impact Driver" (that we just bought that we should have had to begin with working on used bikes with Phillips screws torqued into aluminum) and use the slotted tip.

[Terry Skinner]

For stripped Phillips screws, we used to use a small saw or chisel to turn it into a slotted head type. Then use the "Impact Driver" (that we just bought that we should have had to begin with working on used bikes with Phillips screws torqued into aluminum) and use the slotted tip.

After working at Boeing and having to deal with a lot of Phillips type screws I have come up with some favorite tricks.
Number one is valve grinding compound. Just a dab on the end of the screwdriver tip gives a lot of grip.
Number two is change tips frequently. Don't be afraid to throw a used tip away if it looks used.
Number three is do not use the same tip to tighten the screws that you used to loosen the screw. The metal seems to take a set and when used in reverse they snap.
Number four never use a cheap screwdriver. Always use replaceable tips.
HTH.......Terry

[1941-9N tom]

I use left handed drills, as by the time you get to bottom of bolt, it will most of the time just back out with drill! you just never know what will work! LOL