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Thread: How to: Remove Broken Bolts/Studs

  1. #1
    Senior Member
    Join Date:  Feb 2016

    Posts:    943

    How to: Remove Broken Bolts/Studs

    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:

    BrokenBolt.jpg

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

    516Nut.jpg

    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):

    WeldingBlanket.jpg

    Nut welded on:

    NutWelded.jpg

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

    BoltRemoved.jpg

    Bill Robertson
    #5939

  2. #2
    TGTF (Too Greek to Function) AugustneverEnds's Avatar
    Join Date:  Jul 2012

    Location:  Syracuse, NY area

    Posts:    657

    My VIN:    SCEDT26T5CD010287

    Club(s):   (DMA)

    The reasons to learn how to weld multiply everyday
    Nick A.
    Νικος Αυγουστινατου

    1988 BMW 325iS
    1982 DeLorean DMC-12

  3. #3
    Senior Member
    Join Date:  Jul 2011

    Location:  Ewa Beach, Hawaii

    Posts:    108

    My VIN:    10309

    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

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