Re: need help removing stuck bolt

Posted by David on July 20, 2002 at 11:11:53 from (216.41.148.190):

In Reply to: need help removing stuck bolt posted by Hayne D. Matthews on July 20, 2002 at 10:29:41:

I worked in a automotive machine shop when I was in high school. This is one way we took twisted bolts out of things.

If possible, grind the bolt off flush with the surface of the block. Center punch the bolt as close as possible to the center of the bolt (you will not be perfect here, nobdy ever is, its OK).
Start with a drill bit about half the size of the bolt (or less, here again whatever works for you is fine). Drill through the bolt. This needs to be as straight as possible with the bolt. When you have this done, take a drill bit slightly larger and do the same thing. Keep repeating this step until you hit the treads on one side.
when you reach this point take a long slim punch and sharpen it at an angle. try to "peel" the bolt out of the hole. When the remaoning part of the bolt colapses it will break free and you can pull or screw it out with a pair of needle nose or punc it on thru. Then take a tap and clean up the treads. Usually you will only barely touch the threads.
or if you want, when you get the hole as big as you can without cutting out the cast, take a cutting torch and stick it in the hole let it heat up a short time and hit the oxygen. It will blow the molten bolt out thru the back of what ever you are working on. Then chase the treads again with a tap. Only do this on holes that go all the way through. It will blow back at you if it doesn't. This really works, and hardly touches the cast.

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