DIY | Tricks for removing stubborn or broken bolts

DIY | Tricks for removing stubborn or broken bolts

– Hi this is Davin Reckow with Hagerty. Today I’m gonna show you two
different ways to extract a seized up bolt in these
aluminum timing covers. One stands way up proud
and one’s fairly flushed, and neither one of them are
gonna just simply come out with a pair of vice grips. So for today’s DIY project, we
have fairly simple hand tools and a wrench, pair of vice
grips, and a wire brush. But then we get into a little bit more expensive pieces as well. We have a oxy acetylene
torch, the striker, a good pair of shaded safety glasses, of course a good pair of gloves, and then we also are gonna
be using a MIG welder and then of course a good welding helmet. Okay, so there’s two basic ways that we can heat this aluminum housing up. First one, just plain and
simple using a propane torch. It’ll just take you a little longer. I have a oxy acetylene
torch I’m gonna use today, and it’ll be a little quicker. Now the danger is aluminum will heat up to the point where it will bubble, and it will not really show you that until it’s starting to bubble,
so just be real careful. Take your time and be patient. It’s not going to turn red like steel. So you don’t have a visual indicator. So before I get to heating it, because I wanna see this metal real well I’m gonna take and just
brush this off a little bit to get some gunk out of there. (scraping) And for what I’m doing,
I’m not worried about that little bit of oil, it’ll burn off. Alright, so safety glasses. It’s always a good idea
to use some gloves. It can get a little warm. It better get warm. (clicking) (wooshing) Like I said, you wanna heat this evenly and you don’t wanna get it too hot. (wooshing) Just enough to get it to expand. Aluminum’s gonna expand pretty quickly. (wooshing) Just work it back and forth. It helps clean things out on that thread. And once it’s turning freely, voila. Alright, so you can see
see that was pretty easy. And the thread in the
aluminum is still there. This part’s reusable, it’s all good. On the second one, this is
down a little bit lower. I can probably get on here, but it’s most likely gonna slip off on me. Basically what I’m gonna
do, is I’m gonna take, I’m gonna weld a nut to this
stud using a MIG welder. As it heats up, as it welds to the stud, it’s gonna expand the aluminum. Now granted, that steel’s
gonna expand slightly as well, but the aluminum will expand more and we’ll just back it off using a wrench and that one should come out
as nicely as the first one. (whirring) (buzzing) (creaking) I like to get after it while
the aluminum’s still warm and the MIG isn’t going
to attach to the aluminum. So you don’t have to worry about basically permanently
welding to the, in this case. And actually, even if it was
cast iron, it’ll weld to it but the amount of penetration
is so low it won’t matter. If you don’t own a welder, you certainly could take
it to any welding shop, tell them what you need and they would be more than
happy to do that for you. Obviously when you are using a welder, take all the necessary precautious
from a safety standpoint. Wear proper eyewear, gloves, and protect yourself
from the welding process. If I was going to be welding much longer, I’d certainly make sure I had sleeves on. But for that little bit
the weld is no big deal. (squeaking) There we go, there’s that one. Again, the thread’s in tact. I’ll probably still clean it up with a tap just to make sure it’s nice
and clean for the new parts. And there we have it. Thanks for watching today. Hopefully you found it informative, and if you got any questions leave them in the comments section below.

8 thoughts on “DIY | Tricks for removing stubborn or broken bolts

  1. I have two starter bolts broken off in the block I think the welding technique will work. Any other suggestions?

  2. I was taught way way back to use a rich acetylene flame, and soot up the area where your going to heat. When the part is heated the soot will stay in place. When the soot disappears (burns off) the part is heated to just below the melting point of the aluminum.

  3. Hey Davin, great video of broken bolts. I was a Toolmaker/ welder so I could build my own weldments and fix anything else that was missed up in the process . Stuck , broken bolts, broken taps . I used a wave tig machine table top and a big floor model mig solid and flux core , large stick and a carbon ark that was noisy and the cause of my hearing loss , I had 27 years under the hood and on the handles been retired far 17 years all those long hours and dirty working condition have taken its toll on the old body , aortic valve , heart attack, a-fib , V- tack , ICD IMPLANT , RIGHT SHOULDER replacement for a rotator cuff tear that was massive and could not be repaired . I don’t miss a damn bit of it either. Do enjoy watching you work on that old nailhead , I had a 64 Rivera with a425 great car wish I still had it , later

  4. I have a 2010 FJ cruiser and I broke off two bolts in the transfer case housing trying to install an aftermarket skid plate. The issue is the broken piece is in a blind hole. Any advice on how to get those out? Am I gong to have to take the transfer case apart?

    It’s a steel bolt in an aluminum housing.


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