Extracting Broken Bolts
Most people who own a vehicle or are the least bit handy with home projects will tell you that they have probably had to deal with a broken bolt. If you look up broken bolt you are likely to find a variety of articles discussing the various ways to remove them. However, regardless of the many articles available, there can be a number of different ways to extract that pesky broken bolt.
The most straightforward approach is to use a pair of lock-grip pliers. These are particularly useful if the bolt is just slightly stuck and does not move when turned with a regular wrench. Place the jaws of the pliers around the base of the broken bolt, and squeeze the handle, the force created may be great enough to loosen the bolt from whatever it is attached to.
If the bolt is more deeply embedded, you have several options to try before resorting to more drastic measures. While it may seem like an obvious solution, sometimes just tapping gently around the bolt with a hammer can do the trick, as the vibrations can cause the bolt to work itself loose. If this fails, another method which can be used is to try and cut a slit into the top of the bolt with a cold chisel. Once the slit has been created, use the chisel to wedge itself into the slit and chip away at the edge of the bolt, until you can grip the edges with some sturdy pliers and extract it.
At this point, you may be tempted to turn to heat or drilling to extract the bolt. However, this can be dangerous if not done properly, as heat or power tools used incorrectly can create further damage to the wall or space in which the bolt is embedded, or even warp or melt the bolt. Depending on the position and surrounding material, you may consider using a drill, but the correct size and length of bit must be used - a bit that is too long may become wedged.
In some cases, if none of the above methods have worked and you have decided that drilling is their only option left, there is a precautionary measure you can take to reduce the risk of damage from drilling. Many hardware stores sell “rubber plugs” which consist of rubber epoxy compound and a steel plug at the center. Start by marking the circumference of the broken bolt with a marker. Fill the area around the bolt with the rubber epoxy and insert the steel plug. Once it has set, use the drill to churn out the steel plug and the cemented chunks around it should come right out too.
In order to avoid the hassle of dealing with a seized or stuck bolt, it is best to ensure that they are properly lubricated. Always use a high quality lubricant on any nut or bolt you plan on removing in the future. This will not only reduce the chance of the bolt becoming jammed, but it also makes it easier to extract a broken bolt, as the lubricant will make the area around the bolt slippery, allowing it to move more freely.
Removing a broken bolt can be tricky and time consuming, but armed with the right knowledge, the job doesnt have to be a hair-pulling experience. Taking the time to properly prepare, using the correct tools, following appropriate safety precautions and selecting the best extraction technique for the job, will go a long way in helping you get that broken bolt out.
