How to: Remove Broken Bolts/Studs

[content22207_2]

Finally getting around to putting a carb on my Volvo. Coolant distribution pipe doesn't appear to have ever been removed (all hoses under the intake were marked "Volvo"). Despite using a 3/8 impact gun, one of the bolts snapped off:

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5/16" nut fits a 7mm bolt shank perfectly:

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Welding blanket for protection (I use flux wire, which throws a lot of sparks. On the plus side it doesn't care about coolant all over the place, or being outside):

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Nut welded on:

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Broken bolt removed. I just turned it out with a flat wrench. Obviously heat from the welding broke it free:

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Bill Robertson
#5939

[AugustneverEnds]

The reasons to learn how to weld multiply everyday :meditation:

[cdrusn]

Bill, do you think the flux weld to a nut would work to remove my transmission fill fitting? I stupidly rounded it off and I my stick welder wouldn't hold to the nut and I am afraid that the heat will crack the aluminum housing. My last effort will be to drill it out using an angle drill but I am concerned about not being able to remove all the metal shavings that will fall into the transmission. Any wisdom would be of great help. Garry