Matt Gieselman | Broken bolt, stud or screw removal

Broken bolt, stud or screw removal

If you have ever worked on vintage or even brand new machinery eventually you will break a bolt or a stud.  Below are various methods I’ve used to remove them.

Welding a nut on a broken stud


IMG_1346 While removing an intake manifold from a 60 year old Power Wagon 3 of the 4 bolts broke, luckily the other 2 still had exposed threads and were no problem to remove by threading on a nut and welding the center.

Unfortunately the last one broke flush, first step is to grind off enough metal to expose bare steel to weld on.
IMG_1351 Next place a washer that has a hole the same or slightly smaller diameter than the broken stud.
IMG_1352 Using a welder weld the washer to the top of the broken stud.  Be sure to grind off the slag before the next step.
IMG_1353 Place a nut that is as large as possible on top of the welded washer.
IMG_1354 After welding the nut is glowing red hot, the heat helps loosen the broken stud.
IMG_1356 After about a minute the stud has cooled enough to use a wrench to extract the stud.  The nut isn’t perfectly centered but still the stud came out.
IMG_1358 The finished product is an undamaged bolt hole that doesn’t have to be drilled and tapped.
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