Few things are a bigger pain in the rear then breaking off a bolt or screw while youre in the middle of a project. It can be stressful to not know how to remove broken bolts in these situations. You may also be concerned about whether your project can still be salvaged.
Fear not! With the tips found in this guide, youll be able to make it over this hurdle in no time so you can get back to finishing your project.
What You’ll Need
There are several methods that you can use to fix a broken bolt. You don’t necessarily need a whole toolbox of tools to extract the bolt.
You may not have everything listed below, and if thats the case, Id recommend picking up these tools ASAP as this probably wont be the last time you ever break a bolt.
- Standard chuck power drill
- Left-handed drill bit set
- Vise grips
- Punch in the center
- Hammer
- Bastard cut file
- Easy-Outs
- Compressed air
- Wire brush
- Flashlight
Step I: Assessing The Damage
Before you can remove the damaged bolt, youll need to take a closer look at what youre working with. A flashlight is a good idea for this section, as Murphy’s Law states that the bolt you just broken is likely in a dark or difficult-to-reach area.
If the bolt or screw has snapped, with some threads still exposed then you have an easy job ahead. If you aren’t as fortunate and have nothing to hold onto, then you will need to get a set Easy-Outs. These bits allow you to extract the headless bolt/screw.
Assuming that the bolt broke with a portion of the threads still exposed, youll be able to remove the broken bolt quickly using just a pair of vise grips.
Tighten the thumbwheel of the vise grips to the proper distance (make sure that the grips fit extremely tight on the threads of the bolt) and attach them to the exposed threads. Now, back the bolt out like you would with any other bolt.
If you arent that lucky, its time to reach for your drill and the Easy-Outs.
Step II: Preparing The Bolt
Before you start, file the bolt’s broken head with a bastard filing. You may need to file the broken head of the bolt so that it is flat across the top. In these cases, you can skip this step.
You can tap the bolt once the bolt is flat.
Step III: Tapping The Bolt
Grab your center punch and place it in the center of the bolt. It will be easier to remove the bolt if you are close to the center. This will also reduce the chance of damaging the internal threads.
Once youve found the center, give it a good whack or two with your hammer to mark the center.
Now, put the proper left-handed drill bit into your drill. The Easy-Out kit should include a chart to help you determine which drill bit to use depending on the size of your bolt.
The reason were using left-handed drill bits instead of standard ones is that the threads of the drill bit are reversed from standard threads. To drill into the bolt, youll actually put the drill in reverse.
This way, the drill bit will torque in the reverse direction of the bolt, so you wont have to risk driving the bolt even further into whatever its attached to.
Sometimes, the drill bit may catch on to the bolt and start backing it out for the user. At that point, you can grab it with your vise grips and remove it the rest of the way.
Chances are, youll need to reach for your Easy-Outs to finish the job.
Step IV: Removing The Broken Bolt
Once you have drilled your pilot hole, all that is left is to tap in the appropriate-sized Easy-Out and take out the broken bolt.
Take the Easy-Out and place the tapered tip into the hole youve drilled. You can give it a few taps with your hammer to drive it into the broken bolt. This will allow the Easy-Out to hold the bolt in place.
An Easy-Out can usually be attached to a torque wrench or screwdriver handle to provide extra torque when you are removing the bolt. Attaching a T-handle, ratchet, or screwdriver to the bolt will make it easier if you are unable to remove the bolt with your fingers.
Step V: Cleaning Up
Theres a good chance that metal filings have made their way into the hole you just removed the broken bolt from. To ensure that everything is clean and tidy before you replace the bolt, it’s a good idea to inject compressed air into the hole.
Wrap It Up
There are few noises that the experienced home craftsman dreads more than the sound of a bolt snapping off as youre trying to remove it. It is easy to learn how to remove broken bolts. You will only need a few tools and the tips provided in this guide.
Although you might not have the right tools to complete the task, it’s worth investing in them as soon as possible, as they will be useful for future projects.
