Removing stuck fasteners

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(→Smack it with a hammer #2)
(→References)
 
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My old boss on the Feed Trucks,Dave Simpson,used to
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===Safety===
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{{Warning}}Always wear proper eye, face, body and hand protection when dealing with sharp tools, hammers and chisels, flames or chemicals.
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*[http://www.crankshaftcoalition.com/wiki/Health_and_safety_in_the_shop_or_garage Health and safety in the shop or garage]
  
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Position yourself such that if your hand slips, you're not going to hurt yourself. It is usually safer to push away from yourself (if you slip while pulling, a wrench to the face/ribs does not feel good).  Best practice is to fit yourself with appropriate mechanic's gloves in the event you slip or the fastener abruptly moves, hands can impact adjacent objects.
  
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==General advice==
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No matter what technique is used, when removing stuck fasteners, you need to pay attention to what is turning and what is not.
  
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==General Advice==
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In theory, there should be nothing to stop you finger-tightening a non self-locking threaded fastener until it's snug, or from easily loosening a bolt once it has been fastened snugly. In practice, it's often quite hard to turn some bolts or loosen other bolts, even when they are slack. The reason for this is that dirt gets stuck in the bolt threads, and it gets trapped when you start tightening the bolt, making it harder to turn. This is a warning sign- if you can't finger tighten a bolt until it's snug then there is something wrong. If you are trying to  put a bolt in, then take it out and clean the threads.  If you are trying to loosen or remove a stuck bolt, see if you can access the end of the bolt (opposite end of the bolt head). Put a little grease on the threads before you try again. It's a bad idea to get out the spanner wrench early on to try tightening a bolt that isn't turning smoothly. Even if you get it tightened, that dirt is still in the threads, and it's quite likely that it'll jam the threads when you try to next remove the bolt.
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*No matter what technique is used, when removing stuck fasteners, you need to pay attention to what is turning and what is not.
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*There is no general consensus as to whether steady or intermittent pressure is best for removing stuck fasteners.
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*Keep in mind that fastening hardware stuck together by corrosion is stuck because the corrosion has expanded and tightly bound the fastener. This means a really stuck bolt will not allow penetrating oils in to do any good.
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*There are two effective means to break the friction that corrosion has caused. One is through mechanical movement, a proper good whack with a hammer. The other is through differential heating. Making one part expand more than the other.   
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*With heating, bear in mind axles and other important structures may lose their strength if they are heated much above 300 degrees. If you have the oil and grease starting to smoke, then you are in the 300-degree range.
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*When taking off cylinder head studs, look at the base. If you see erosion into the stud at the block surface, odds are pretty good you will break the stud.
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* Whatever system you use, once you have a hold of the bolt,stud, or whatever, try rocking it forward and reverse a little at a time. If you can get it to move, it is more likely to come out. An older mechanic said always try to tighten a little before you loosen. Remember, if it moves, you are half way home. Also, brake fluid works great as a penetration oil.
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==Smack it with a hammer==
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==Methods for removing stuck/frozen fasteners==
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Though this may not be practical for all situations, a stuck bolt can often be broken loose simply by hitting it on the head with a hammer. In such a case, a brass drift may be helpful. Drifts of varying lengths can be made from brass bar, and used to access hidden bolts. Brass is used because it's softer, and thus less likely to damage the head of a fastener(However the problem with brass is it will absorb some of the shock of the blow from the hammer, so one may need to use a melt drift for maximum shock to the bolt). Brass hammers are also available and one about 3 or 4 lbs. in weight is good for this.
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Most stuck fasteners are stuck because of corrosion, usually [[rust]]. There are at least three effective methods to break loose a fastener:
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*Mechanical movement -- often simply a whack with a hammer.
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*Differential heating -- making one part expand more than the other.
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*Chemical penetrants.
  
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If I could have only one chemical tool, it would be "Liquid Wrench".  Note that when trying to loosen rusty parts, it's important to first remove as much of the rust as possible with a wire brush.  Once it's as clean as a wire brush will get it, apply Liquid Wrench, then give the piece repeated light taps with a hammer for ten or fifteen seconds; this helps work the Liquid Wrench into the crevices. Wait two minutes, then repeat the Liquid Wrench/tapping procedure.  After repeating the procedure 3 or 4 times, THEN try to loosen it with one swift blow.  Sometimes it won't work, but the majority of the time, your patience will allow you to not only remove the rusted nuts and bolts, but to possibly even reuse them.
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==Mechanical means==
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===Tighten, then loosen===
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In some cases simply tightening the fastener and then loosening it will do the trick. In some cases, wiggling the fastener back and forth may be helpful.
  
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Many people recommend "PB Blaster", which led to me trying it - it did an excellent job for me. An overnight soak-in is an important step.
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===Strike it with a hammer===
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Though this may not be practical for all situations, a stuck bolt can often be broken loose simply by hitting it on the head with a hammer. In such a case, a brass drift may be helpful. Drifts of varying lengths can be made from brass bar, and used to access hidden bolts. Brass is used because it's softer, and thus less likely to damage the head of a fastener. Brass and lead hammers are also available and one about 3 or 4 lbs. in weight is good for this.
  
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==Smack it with a hammer #2==
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Another option is to get a wrench or ratchet onto the stuck fastener, and then hit the wrench or ratchet with a hammer, creating a manual impact wrench.
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If you can access the nut, try hitting each flat of the nut with a drift punch and ball peen hammer.
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===Smack it with a hammer #2===
 
This method is useful when dealing with a bolt that is rusted very tightly. A lot of people will get a wrench or ratchet and push against it with a steady force. Doing this will more than likely break off the bolt head of a rusty bolt.  
 
This method is useful when dealing with a bolt that is rusted very tightly. A lot of people will get a wrench or ratchet and push against it with a steady force. Doing this will more than likely break off the bolt head of a rusty bolt.  
  
 
The best thing to do is to get a wrench or ratchet on it, and either hit it with your hand or a hammer several times.  The sudden force will break the bolt loose with less of a chance of twisting off the head.
 
The best thing to do is to get a wrench or ratchet on it, and either hit it with your hand or a hammer several times.  The sudden force will break the bolt loose with less of a chance of twisting off the head.
  
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If you can get to the nut, try hitting each flat of the nut with a drift punch and ball pein hammer.
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Some times a homemade impact wrench will work, get a cheap wrench that fits tight and hit it with a hammer, watching carefully that it isn't damaging the fastener. It's important when loosening this way to use a tight fitting wrench like a 6-point box end, as a loose fitting one will round the bolt head.
  
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Some times a home made impact wrench will work, get a cheap wrench that fits tight and hit it with a hammer watching carefully that it isn't coming off the fastener. It's important when loosening this way to use a tight fitting wrench as a loose fitting one will round the bolt head.
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===Tap it for a few minutes===
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Lightly tap on rusted fasteners for several minutes, apply a little penetrating oil, lightly tap a little more, then remove the rusted fastener.
  
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==Tap it for a few minutes==
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===Metric method===
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Lightly tap on rusted fasteners for several minutes, apply a little penetrating oil, lightly tap a little more, and remove the rusted fastener.
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Hammer a close-fitting metric socket tightly on a SAE nut, or vice versa. Then use breaker bar socket wrench (or longest you can fit in a cramped space) to turn it.
  
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==Metric Method==
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There is a product that works basically the same way, but the inside of the sockets are lined with sharpened flutes that are also angled to dig further into the rusted nut or bolt as you turn the wrench.  These are called '''''bolt extractor''''' sockets; they bite into rounded and rusty bolts and nuts, as the flutes are sharp and point counter clockwise.  Think of what you would get if you made a mold of an extractor drill bit. See '''[[Removing stuck fasteners#Special tools|Special tools section]]'''.
  
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Hammer a close-fitting metric socket tightly on a SAE nut, or vice-versa. Then use breaker bar socket wrench (or longest you can fit in a cramped space) to turn it.
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==Temperature differential==
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===Freezing===
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Loctite makes a product called [http://loctitefreezeandrelease.com/instructions.htm Freeze and Release] that may work for certain situations. It's basically a sub zero spray that freezes on contact.
  
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I've seen a product that works basically the same way, but the inside of the sockets are lined with sharpened flutes that are also angled to dig further into the rusted nut or bolt as you turn the wrench.  These are called metric sockets, and bite extremely well into round and rusty bolts and nuts, as the flutes are sharp and point counter clockwise.  Think of what you would get if you made a mold of an extractor drill bit.
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===Hot and cold===
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==Hot and Cold==
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This method uses alternating heating and cooling. The resulting expansion and contraction is thought to break a fastener loose from the grip of rust.
 
This method uses alternating heating and cooling. The resulting expansion and contraction is thought to break a fastener loose from the grip of rust.
  
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#While it's still red-hot, squirt it with water.
 
#While it's still red-hot, squirt it with water.
 
#Repeat the heating and cooling process again with the torch and water.
 
#Repeat the heating and cooling process again with the torch and water.
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*When using the "Hot and cold" method be sure to follow proper safety procedures, specifically:
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**Wear proper safety attire including welder's gloves and safety goggles.
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**As with any time you use any flammable ignition sources, have a fire extinguisher within arm's reach.
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If you use any type of penetrating oils they should be removed thoroughly first, they tend not to let the water do its thing when the hot and cold method is used. Remember- heat, and '''then''' use the water. Do this several times. 
  
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Too much heat will destroy the temper of a fastener. Important fasteners like used on the suspension, steering and brake systems should be replaced if there is any question as to the condition.
  
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When using the "Hot and Cold Method" be sure to follow proper safety procedures. Specifically:
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===Heat the nut method===
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*Wear proper safety attire including welder's gloves and safety goggles.
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Heat the '''nut''' with a torch until red hot, cool the bolt with a good shot of spray-on rust remover then remove the nut while still hot.  Heating the nut thermally expands it, while the rust remover (which is a refrigerant) thermally contracts the bolt.  Be careful and use gloves as the nut and your wrench will be hot.
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*As with any time you use any flammable ignition sources, have a fire extinguisher within arm's reach.
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When using the 'Hot and Cold Method', care should be taken to ensure that only the bolt is heated. If the nut is heated and cooled, the nut will likely become seized tighter.
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===The heat and paraffin wax method===
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When using this method use this Hot and Cold method FIRST... If you use any type of penetrating oils, they tend not to let the water do it's thing when the hot and cold method is used. Please remember heat, & then use the water... several times. I think the water becomes steam which has plenty of penetrating power to get in tight places. You never heard of penetrating oil engines, but everyone has heard of steam engines.
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..
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Too much heat will destroy the temper of the bolt.  Important bolts (brakes) should then be replaced with new as the untempered one if reused could fail.
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==The heat and paraffin wax method==
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#Heat the bolt with a torch.
 
#Heat the bolt with a torch.
 
#Touch the threads with paraffin wax. Ensure that the bolt is situated such that the wax will run down into the mating threads.
 
#Touch the threads with paraffin wax. Ensure that the bolt is situated such that the wax will run down into the mating threads.
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#Let the welded nut cool completely without using any water or spray. The bolt will contract and break the grip of the rust.
 
#Let the welded nut cool completely without using any water or spray. The bolt will contract and break the grip of the rust.
  
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Some more info on welding on nuts.
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===Some more info on welding on nuts.===
  
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A tig welder is the welder of choice.
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*A TIG welder is the welder of choice.
  
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It is critical to put some penetration oil like Kroil (and not WD-40) on as it cools just low enough for the oil to not just boil off.  This will draw oil into the hole.  This is the only time I have seen penetrating oil actually penetrate a stuck bolt.
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*It is critical to put some penetration oil like Kroil (and not WD-40) on when it has cooled enough for the oil to not just boil off.  This will draw oil into the threads.   
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For more information refer to this webpage http://idisk.mac.com/forever4/Public/pages/studremoval.htm
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==Penetrating and lubricating oils==
 
==Penetrating and lubricating oils==
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Penetrating oil is an extremely low-viscosity oil that can penetrate into the area between threads on a fastener. A stuck fastener is often heated, sprayed with penetrating oil, and then tapped with a hammer.
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[[File:Pb blastergallon.jpg|thumb|left|444px|PB Blaster penetrant, also available in aerosol cans]] [[File:W-d 40.jpg]]<br style="clear:both"/>
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Penetrating oil is a low-viscosity oil that can penetrate into the area between threads on fasteners. A stuck fastener is sometimes repeatedly heated, sprayed with penetrating oil, and then tapped with a hammer.  
  
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Some comments on penetrating oils.  WD-40 is not a penetrating oil, it is a corrosion preventative.  There is problem with the idea that penetrating oils can penetrate rusted together parts.  I have done some testing.  For a whole week I put Kroil on a head studs.  I than pulled one stud from the head that felt like it wanted to come.  As I suspected, it was dry.  If the bolt is free enough for penetrating oil to seap through then it will come out without any oil.  
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If heating or hammering is not possible the penetration can be improved by first spraying brake cleaner on the stuck fastener and following with the penetrating spray before the brake cleaner has evaporated. The solvent penetrates better than oil and will pull some oil with it.
  
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If you really want to get studs out you need to use shock (hammer hits) and or carefull application of heat cycles.
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A decent penetrant is "Liquid Wrench". Another that is always at the top of the list is PB Blaster"- it has surprised many users with how well it works. Note that when trying to loosen rusty parts, it's important to first remove as much of the rust as possible with a wire brush. Once it's as clean as a wire brush will get it, apply Liquid Wrench, then give the piece repeated light taps with a hammer for ten or fifteen seconds; this helps work the penetrant into the crevices. Wait two minutes, then repeat the Liquid Wrench/tapping procedure. After repeating the procedure 3 or 4 times, ''then'' try to loosen it with one swift blow. Sometimes it won't work, but the majority of the time, your patience will allow you to not only remove the rusted nuts and bolts, but to possibly even reuse them.
  
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Some penetrating oils that are recommended by hotrodders:
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A longer soak time is better than a shorter soak time, with repeated reapplications if possible.
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===Some recommended penetrating fluids===
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*Acetone mixed with Automatic Transmission Fluid '''<font size="5"><nowiki>*</nowiki>'''</font>
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*Acetone mixed with Power Steering Fluid
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*Air tool oil
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*BG In Force
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*[http://www.break-free.com/products/products_breakfreeclp.asp?catalog=civil Break-Free CLP]
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*[http://www.blueworksbrand.com/products/penetrant/ Blue Works Industrial Grade Penentrant] by WD40
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*CRC Industries:
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**[http://www.crcind.com.au/catalogue.nsf/web_brands/CRC+5-56?openDocument 5-56] 
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**[http://www.crcindustries.com/auto/content/prod_detail.aspx?PN=05002&S=Y Freeze-Off]
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**[http://www.crcindustries.com/auto/content/prod_detail.aspx?PN=401712&S=Y Knock'er Loose]
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**[http://www.crcindustries.com/auto/content/prod_detail.aspx?PN=05330&S=Y Ultra Screwloose]
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*Diesel fuel
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*[https: //www.lawsonproducts .com/Drummond/Open-and-Shut-Nut-and-Bolt-Loosener-and-Rust-Penetrant/DA6152.lp Drummond Open and Shut]<ref>https: //www.hotrodders .com/forum/best-penetrating-lubricant-147009.html#post1033340</ref>
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*[https: //www.lawsonproducts .com/Drummond/Open-and-Shut-NutBolt-LoosenerRust-Penetrant/DA7671.lp Drummond Open and Shut]<ref>https: //www.hotrodders .com/forum/best-penetrating-lubricant-147009.html#post1033340</ref>
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*[http://www.lubecorp.com/products/excel_440_super_lubricant.html Excel 440 Super Lubricant]
 
*[http://www.bilthamber.com/ferrosol.html Ferrosol]
 
*[http://www.bilthamber.com/ferrosol.html Ferrosol]
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*[http://pbblaster.com/store/moreinfo.cfm?Product_ID=1 PB Blaster]
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*[http://getgibbs.com Gibbs]
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*[http://kanolabs.com Kroil]
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*GM General Purpose Penetrant and Heat Valve Lubricant #1052627
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*[http://www.wd40.com WD-40]
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*Hilco Lube #5035
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*[http://www.armorholdings.com/productsdiv/break_free.asp Break Free]
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*[http://www.howeslube.com/products/index.php/category/40 Howes]
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*[http://justicebrothers.com/pages/products/products_specialty.htm JB-80]
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*[http://kanolabs.com Kroil/Aerokroil]
 
*[http://www.gunk.com/lubricants.asp Liquid Wrench]
 
*[http://www.gunk.com/lubricants.asp Liquid Wrench]
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*Diesel oil/fuel. Apply and allow to soak for period of time. Then strike head of bolt (if practial) with hammer blow.
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*LPS:
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**[http://www.lpslabs.com/product_pg/lubricants_pg/LST.html LST]
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**[http://www.lpslabs.com/product_pg/lubricants_pg/KB88.html KB 88]
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*[http://mousemilk.com/ Mouse Milk]
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*[http://www.orbindustries.com/penetrants-lubricants.php Nuts Off]
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*Paraffin wax
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*[http://pbblaster.com/store/moreinfo.cfm?Product_ID=1 PB Blaster]
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*[http://www.plusgas.co.uk/ PlusGas]
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*[http://www.ronsonstore.com/multilube.aspx Ronson Multi-Lube]
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*[http://www.schaefferoil.com/specialty/190_Penetro.html Schaeffer Penetro 90]
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*[http://www.seafoamsales.com/deepCreep.htm Seafoam Deep Creep]
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*[http://www.uchem.co.uk/products.php?section=OIL&type=cat Unilease]
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*[http://www.wd40.com/ WD-40]
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*Zep 45
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==='''<font size="5"><nowiki>*</nowiki>'''</font> Commercial penetrating fluids compared to ATF/acetone mix===
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Machinist's Workshop magazine actually tested penetrants for break out torque on rusted nuts. They arranged a subjective test of all the popular penetrants with the control being the torque required to remove the nut from a "scientifically rusted" environment.
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{| class="wikitable"
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|-
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! Penetrant !! Average load
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|-
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| None || 516 lbs.
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|-
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| WD-40 || 238 lbs.
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|-
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| PB Blaster || 214 lbs.
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|-
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| Liquid Wrench || 127 lbs.
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|-
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| Kano Kroil || 106 lbs.
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|-
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| ATF/acetone mix || 53 lbs.
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|}
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The ATF/acetone mix was 50/50 automatic transmission fluid and acetone. Liquid Wrench is shown in this test to be about as good as Kroil for about 20% of the price.  
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Info from [http://www.hotrodders.com/forum/a-1558916-singlepost32.html here].
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==Corrosion removers==
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Removing corrosion from metal fasteners can help in their removal.  When the iron in steel converts to iron oxide, or "rust", it swells, which can cause parts to seize in place.  Rust can also distort the head of a fastener hampering efforts to securely grip the head with tools.
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Corrosion Removers work in various ways depending on their chemistry.  Some require parts to be soaked, others can be sprayed on applied as a gel.
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Methods of corrosion removal include:
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*Mild household acids - typically require a multi-hour soak
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**Vinegar (Acetic Acid)
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**Citric Acid - Usually available in bulk crystal form.
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*Commercial proprietary formulas
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**[http://www.evapo-rust.com/ Evapo Rust] Requires multi-hour soak
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**[http://www.boeshield.com/ Boeshield Rust Free] Sprayed on.
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*Electronic Rust Removal - Requires a bucket, sodium carbonate (washing soda), and a 12v battery charger.
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**[http://blog.makezine.com/archive/2008/09/rust_removal_using_electr.html MAKE: Rust Removal using electrolysis]
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**[http://www.ehow.com/way_5513137_electronic-rust-removal.html eHow: Electronic Rust Removal]
  
 
==Special tools==
 
==Special tools==
 +
*A pneumatic or electric impact wrench can loosen most any fastener, given enough tool capacity and psi. But that is not always going to be on hand. The following are some ideas that may work:
 
*Flameless heat tool useful for removing rusted or broken fasteners: [http://www.theinductor.com/ The Inductor].
 
*Flameless heat tool useful for removing rusted or broken fasteners: [http://www.theinductor.com/ The Inductor].
 
*Left-handed drill bits, or screw extractors, can be used to remove many fasteners.
 
*Left-handed drill bits, or screw extractors, can be used to remove many fasteners.
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[[File:Left hand drill bits.jpg|frame|left| Left hand drill bits]]
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<br style="clear:both"/>
 
*For stubborn nuts, try a nut splitter. It will crack the nut without damaging the bolt inside.
 
*For stubborn nuts, try a nut splitter. It will crack the nut without damaging the bolt inside.
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*An impact driver can be used to loosen frozen nuts or bolts. Hand-held impact drivers typically have slotted and Phillips headed bits, as well as a socket fitting. The bit or socket is placed on the stuck fastener, and the other end of the impact driver is struck with a hammer. The impact of the hammer strike loosens the fastener, the downward force keeps the bit in its place, and the impact driver turns the force of the hammer strike into a sudden torque on the stuck fastener.
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*A rechargeable impact drill/driver can be used to loosen frozen fasteners if they are within the capacity of the tool.  
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*[http://www.sears.com/sr/javasr/product.do?cat=Hand+Tools%2C+General+Purpose&pid=00952166000&vertical=TOOL&subcat=Bolt-Out%2C+Taps+%26+Dies&BV_UseBVCookie=Yes Craftsman 10 pc. Damaged Bolt/Nut Remover Set, Low Profile Bolt-Out Sears item #00952166000]. They are useful for when the bolt head is rounded off, or there is no room to beat a socket or wrench on to it, or when a torch is not available.
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*Hand-held impact drivers typically have slotted and Phillips headed bits, as well as a socket fitting. The bit or socket is placed on the stuck fastener, and the other end of the impact driver is struck with a hammer. The impact of the hammer strike loosens the fastener, the downward force keeps the bit in its place, and the impact driver turns the force of the hammer strike into a sudden torque on the stuck fastener.
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*Another good brand of bolt extractor is Extractor, has a little bit more "bite" than the Craftsman and Irwin ones
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*[http://www.sears.com/sr/javasr/product.do?cat=Hand+Tools%2C+General+Purpose&pid=00952166000&vertical=TOOL&subcat=Bolt-Out%2C+Taps+%26+Dies&BV_UseBVCookie=Yes Craftsman 10 pc. Damaged Bolt/Nut Remover Set, Low Profile Bolt-Out]. These can be useful for when the bolt head is rounded off, or there is no room to beat a socket or wrench on to it, or when a torch is not available.
 +
*Another good brand of bolt extractor is named '''Extractor''', it supposedly has a little bit more "bite" than the Craftsman and Irwin extractor tools.
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*Hotrodders forum thread on the [http://www.hotrodders.com/forum/does-work-grabit-seen-tv-155731.html "GrabIt"] extractor tool, as seen on a late-night infomercial.
 +
[[File:Sockets 003.jpg|thumb|left|300px|Damaged or frozen fastener removal sockets]]<br style="clear:both"/>
 +
*A rubber band placed between a stripped screwhead and a screwdriver can help get enough grip on the remaining metal.
 +
*If you're removing the remains of a broken zerk fitting/grease nipple, then a cheap Philips head screwdriver can be hammered in sufficiently to grip the hollow barrel and unscrew like normal.
  
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==Tips for broken-off bolt heads==
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===Instructions for making an impact-type screw removal tool===
 +
This is designed to remove a fastener that has a stripped head.
 +
*Get an aircraft rivet gun (note: not a tubing cutter, they're too fast) that has less than 2000 bpm (blows per minute).
 +
*Get one of the rivet gun sets, and weld a piece of 3/4" hex stock to the working end of the set then weld an apex tip holder to the hex stock (of course you need an air compressor, 100 psi is just fine).
 +
*Put a Phillips tip in the apex holder (prior to that grind a little off the tip as they usually are slightly too long; this will allow the tip to drop farther into the screw head so it will pick up what is left of the flutes in the head).
 +
*Optional: Use some valve grinding compound on the tip of the Phillips head bit. The valve grinding compound will help the bit grip the fastener.
 +
*Put the whole thing together and insert the tip into the screw head. Slowly pull the trigger on the rivet gun, while at the same time putting pressure on the box end wrench you have installed on the hex part of your tool, making sure to keep pressure on the gun handle so it won't jump out of the work.
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*One word of caution: even though this works almost 100% of the time, it is possible (if the screw is into a plate nut) to twist the plate nut off its mount.
 +
'''[[Removing stuck fasteners#Metric method|Return to above]]'''
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 +
==Tips for broken off bolt heads==
 
*If enough of the bolt remains, try to grab it with locking pliers or a pipe wrench.
 
*If enough of the bolt remains, try to grab it with locking pliers or a pipe wrench.
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*Try to saw a groove in it, so that a flat-head screwdriver can be used to turn it. Use an impact screwdriver if you have one, it will work alot easier.
+
*Try to saw a groove in it, so that a flat-head screwdriver can be used to turn it. Use an impact screwdriver if you have one, it will work a lot easier.
 
*Take a 12-point socket that is just larger than the shaft of the bolt, and beat it down onto the bolt with a hammer. Turn it out with a ratchet. When finished, put the socket in a vice, and tap out the broken bolt.
 
*Take a 12-point socket that is just larger than the shaft of the bolt, and beat it down onto the bolt with a hammer. Turn it out with a ratchet. When finished, put the socket in a vice, and tap out the broken bolt.
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*If a bolt is broken off below the surface, build it up with a welder until there is enough to which to weld a nut. If this brakes off try it again, this method is the best, the heat and cool cycle of the tig weld will loosen the fastener in the stuck piece.
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*If a bolt is broken off below the surface, build it up with a welder until there is enough to which to weld a nut. If this breaks off try it again; the heat and cool cycle of the TIG weld will loosen the fastener in the stuck piece.
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*Center punch the broken bolt and drill the bolt head using a left hand drill bit about half the diameter of the bolt. As the bolt head is drilled, most of the time the bit will bite into the bolt head and spin the broken bolt out.
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I have also have had good luck by center punching the broken bolt and using a left hand drill bit about half the diameter of the bolt and as it is drilling most of the time the bit will bite and spin the broken bolt out.
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==Miscellaneous tips==
 
==Miscellaneous tips==
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*A pipe wrench will grip rounded off fasteners.
 
*Weld a piece of metal to the top of the bolt, to use as leverage when loosening.
 
*Weld a piece of metal to the top of the bolt, to use as leverage when loosening.
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*If the slot of a round-headed screw is stripped, file two flat edges in it. Then, it can be turned with an adjustable wrench. Or, use a hacksaw to file a new slot at a right angle to the existing one.
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*If the slot of a round-headed screw is stripped, file two flat edges in it. Then, it can be turned with an adjustable wrench or Vice Grips. Or, use a hacksaw to file a new slot at a right angle to the existing one. Depending on the size of the fastener, using a Dremel tool or a die-grinder with a fiber wheel, carefully grind a large, deep slot in the head of the fastener, and before it cools, use a large screwdriver or impact driver to remove it. The fastener is obviously not reusable at this point, but it can possibly save the difficulty of having to drill and tap a new hole through a hardened, broken-off easy-out.  
 
*Six-point sockets will grip better on hex nuts and bolts than 12-point sockets.
 
*Six-point sockets will grip better on hex nuts and bolts than 12-point sockets.
 
*Drill and tap the bolt to run another, smaller bolt down the center. A bit about half the diameter of the headless, stuck bolt is usually sufficient. Use a jam nut on the small bolt and lots of penetrating oil.
 
*Drill and tap the bolt to run another, smaller bolt down the center. A bit about half the diameter of the headless, stuck bolt is usually sufficient. Use a jam nut on the small bolt and lots of penetrating oil.
 
*If it is a stripped screw, either slotted or Phillips, try using a dab of valve grinding compound on the tip of the screwdriver. The valve grinding compound will help with friction to hold the tip onto the fastener when turning.
 
*If it is a stripped screw, either slotted or Phillips, try using a dab of valve grinding compound on the tip of the screwdriver. The valve grinding compound will help with friction to hold the tip onto the fastener when turning.
 
*Use a piece of tubing that fits in the bolt hole (OD) with the center (ID) the size of the drill bit. This will keep the drill bit centered in the bolt, when you use the EZ out.
 
*Use a piece of tubing that fits in the bolt hole (OD) with the center (ID) the size of the drill bit. This will keep the drill bit centered in the bolt, when you use the EZ out.
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*Where access allows, put a box end wrench over a stripped nut or hex bolt head, then use a centrepunch on the corners of the hex to spread the metal and wedge it in the wrench.
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*Where access allows, put a box end wrench over a stripped nut or hex bolt head, then use a center punch on the corners of the hex to spread the metal and wedge it in the wrench.
 
*If the bolt or stud breaks off below the surface, try this method. Using a high grade bolt of same size, grind off the threaded end until the bolt will fit into the hole and touch the broken bolt.  Using an electric welder, clamp the "electrode" bolt in the stinger. This works best if someone is there to help you by turning the welder on and off. With the stinger bolt inserted into the broken bolt hole and firmly against the broken bolt, have the power turned on just long enough to fuse the stinger bolt to the broken one. You might want to practice this technique on the bench to get the power and timing right. Once they have cooled for a few minutes, but are still hot enough to burn skin, place a wrench on the slave bolt and turn them out.
 
*If the bolt or stud breaks off below the surface, try this method. Using a high grade bolt of same size, grind off the threaded end until the bolt will fit into the hole and touch the broken bolt.  Using an electric welder, clamp the "electrode" bolt in the stinger. This works best if someone is there to help you by turning the welder on and off. With the stinger bolt inserted into the broken bolt hole and firmly against the broken bolt, have the power turned on just long enough to fuse the stinger bolt to the broken one. You might want to practice this technique on the bench to get the power and timing right. Once they have cooled for a few minutes, but are still hot enough to burn skin, place a wrench on the slave bolt and turn them out.
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*For removing stubborn Philips-head screws, wet the tip of the screwdriver or screwdriver bit, a little bit of spit will do, and dip the bit into a bit of abrasive cleanser - like Comet or Ajax.  Use enough to cover the tip of the screwdriver. The abrasive in the cleanser gives the tip of the screwdriver a little added "bite" and it's less likely to slip out of the screw.
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*For removing stubborn Phillips-head screws, wet the tip of the screwdriver or screwdriver bit, a little bit of spit will do, and dip the bit into some valve grinding compound or abrasive cleanser like Comet or Ajax.  Use enough to cover the tip of the screwdriver. The abrasive gives the tip of the screwdriver a little added "bite" and it's less likely to slip out of the screw.
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*Intermittent pressure, such as an impact wrench seems to be better suited to this job. A device that we built that works on screws that some one has stripped out the head. Get an aircraft rivet gun (note: not a tubing cutter, they're to fast) that has less than 2000 bpm (blows per minute). Get one of the rivit gun sets, and weld a piece of hex stock 3/4" to the working end of the set then weld an apex tip holder to the hex stock ( of course you need an air compressor 100lbs is just fine) put a Philips tip in the apex holder (prior to that grind a little off the tip as they usually are slightly too long; this will allow the tip to drop farther into the screw head so it will pick up what is left of the flutes in the head). Put the whole thing together and insert the tip into the screw head slowly pull the trigger on the rivit gun, while at the same time put pressure on the box end wrench you have installed on the hex part of your tool, making sure to keep pressure on the gun handle so it won't jump out of the work. One more word of caution -- even though this works almost 100% of the time it is possible (if the screw is into a plate nut) to drive the plate nut off its mount.
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*If you break off the head of the bolt, grind the remainder out with care using a TrueBite carbide bit and a high-speed rotary tool (Dremel MotoTool or similar). See [http://www.truebite.com/remove/ Removing Broken Bolts And Studs] for details and instructions.
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*If you break off the head of the bolt, grind the remainder out with care using a TrueBite carbide bit and a high-speed rotary tool (Dremel MotoTool or some such) - see http://www.truebite.com/remove/ for details and instructions.
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*With heating, bear in mind axles and other important structures may lose their strength if they are overheated and seals can be melted or degraded to the point of being useless. If you have the oil and grease starting to smoke, then you are in the 300-plus degree range.
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*Besides the Comet cleanser tip, another way to give a screwdriver more grip on a screwhead is to dip the tip of the screwdriver into a little valve grinding compound, then apply the screwdriver to the screwhead. Works well anywhere you need a little more traction to get that stripped screwhead out or sometimes can be used on a closed end wrench and slightly rounded off bolt head.
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*When taking off cylinder head studs or bolts, look where it passes into the head. If you see erosion into the fastener at the block surface, odds increase that the stud or bolt will break on removal.
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*Whatever system you use, once you have a hold of the fastener, try rocking it forward and reverse a little at a time. If you can get it to move, it is more likely to come out. An older mechanic said always try to tighten a little before you loosen. Remember, if it moves, you are half way home.  
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==References==
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*Use the largest cobalt drill bit (that just covers the ID of the nut) to drill through the nut- parallel to the bolt- then used a chisel to turn/peel the nut off of the bolt.
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*[http://www.hotrodders.com/forum/tip-day-33-a-75849.html Tip of the day #33], ''Hotrodders Bulletin Board'', December 10, 2005.
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*[http://en.wikipedia.org/wiki/Penetrating_oil Penetrating oil], ''Wikipedia'', retrieved July 15, 2006.
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*[http://www.chevytrucks.org/tech/stuckbolt.htm Stuck Bolts], ''ChevyTrucks.org'', retrieved July 16, 2006.
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*[http://www.pumaracing.co.uk/tooluse.htm Removing Stuck Fasteners] ''PumaRacing.co.uk'', retrieved July 16, 2006.
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*[http://www.rd.com/content/openContent.do?contentId=17889 Loosening Stubborn Nuts, Bolts, and Screws] ''Reader's Digest'', retrieved July 21, 2006.
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Latest revision as of 18:03, 1 September 2023

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