How to install studs in cork boots

Remove rusted bolts quickly and easily

A bolt is a piece of metal shaped like a screw that is used to hold steel girders. However, during construction, it is very likely that the bolts could break every now and then. While it rarely happens, the likelihood increases when the work is rushed or done by inexperienced workers. Hence, it is always helpful to understand how to remove broken bolts.

Method 1: Remove the bolts by using a counterclockwise extractor

There are special bolt removal sets, so-called left-hand extractors or screw extractors, which are available in hardware stores. These kits are great for removing bolts.

Step 1:

Position the pointy end of a nail on the center of the broken bolt and hit it with a hammer. This marks the center of the broken bolt. This way you can drill through the center of the stud without running the risk of damaging the grooves on the broken stud. In this way, it can be easily made possible to remove the bolt in the next steps.

Step 2:

Now, with a left-hand extractor drill, drill a hole through this marking into the bolt to remove the bolt. Left extractor drills have an opposing thread. This is why you need to adjust your drill bit so that it rotates backwards and drives the bolt into the beam. The reason for using a left handed drill bit is because it will rotate in the opposite direction of the broken screw. This prevents the screw from narrowing and makes it difficult to remove the bolt.

Ideally, the left-hand extractor drill gets caught; so you can unscrew the bolt so far that you can grip it with pliers or a vice handle. You can now remove the bolt by gently jerking and pulling.

However, you should make sure beforehand that you are using a drill that is exactly the right size. A table is included with the extraction kit that indicates the size of the screw for which each drill bit is intended. If the twist drill used is too large, there is a great risk of damaging the grooves of the bolts. If the drill used is too small, you will have to use a weaker extractor. However, this entails a high risk of termination in the middle of the procedure.

Step 3:

Insert the correct size extraction attachment into the hole you just made. Depending on the type of extraction kit you purchased, this drill bit has two differently shaped ends. One end is pointed, the other has a T-handle head or a hexagonal head. Since the puller itself is left-handed, it is inserted counterclockwise into the screw. Also, since the extractor is pointed, it is best to drive it in with a hammer.

Step 4:

Now you can remove the broken bolt. If you tighten the puller, the conical end is caught and the torque forces act on the bolt. Once the puller is stuck, you can remove the bolt.

Continue turning the puller counterclockwise until the screw is completely removed from the countersunk area.

One should not rush this process. Otherwise you run the risk of damaging the bolt and locking it further. You even run the risk of damaging the item from which you are trying to remove the bolt. It is also a good idea to use the extractor as gently as possible. They are made of hardened steel. A broken extractor would therefore be much more difficult to drill.

Step 5:

You should remove any metal filings. Throughout the process, it is very likely that metal fillings could come out of the bolt. If you intend to use a new screw to replace the broken screw, you must first remove all chips and fillings. You can do this simply by using compressed air or a magnet.

You can also use a penetrating lubricant for the procedure outlined above. These fluids are excellent screw removers and can make the bolt removal process a lot easier.



Option 2: remove studs with a welding machine

Step 1:

Position the sharp end of a nail on the center of the broken bolt and strike with a hammer. This marks the center of the broken bolt.

Step 2:

Now drill a hole through this mark in the bolt. You should use a drill bit almost a quarter the diameter of the screw to drill it out. This extraction technique works for bolts that are excessively rusted because such bolts cannot be removed with a puller. So there is no need to worry about the screw being tightened with a right-handed person.

Step 3: Now you have to screw a hex nut onto the broken screw. Use any exposed grooves on the screw and tighten the nut. The nut needs to be snug, but shouldn't be screwed all the way down. Leave it half a turn from the stop so that there is a gap between the bolt and the surface.

Step 4:

In the next step you have to weld the nuts to the screw. This weld seam is made quickly, but you shouldn't do this job if it is the first time. You should either let an experienced person do the welding or practice welding beforehand with other objects.

You should be careful if the surface that the bolt is embedded in melts and bonds with the screw. This method is particularly effective when the surface is made of aluminum, as it does not easily weld to steel.

Step 5:

Now you can simply remove the bolt. After cooling down sufficiently, the hexagon nut has become the new screw head and can be easily removed with a wrench etc.

The weld is quite strong, but not unbreakable. In the case of screws that are severely corroded, it may be necessary to weld the screw back on several times.

To break through the rust, try moving the bolt slowly back and forth at the beginning. Even if it begins to loosen up, you need to keep applying force in both directions. To make it easy for you to remove the bolt, you should apply more counter-clockwise pressure.

If the effort of the methods described above is too much for you, we have a tip. WD-40 has a special penetration spray specially developed for loosening rusted and broken screws. On our product page you can find out more about the WD-40 Specialist high-performance rust remover and all of our other Specialist products.


By Andrii -