If you’ve ever stripped a bolt, you know how frustrating it can be. You can’t get a grip on it to remove it, and it can feel like you’re stuck. However, there are a few tricks you can try to remove a rounded bolt without damaging the bolt or the surrounding area. In this article, we’ll show you how to do it.
First, try using a pair of vice grips. Vice grips are a type of pliers that have a serrated jaw that can grip onto the bolt. Once you have a good grip on the bolt, you can try to turn it out. If the bolt is too tight, you may need to use a cheater bar or a pipe wrench to get more leverage.
If the vice grips don’t work, you can try using a bolt extractor. A bolt extractor is a tool that is designed to remove stripped bolts. Bolt extractors come in a variety of sizes, so you can choose one that is the right size for the bolt you are trying to remove. To use a bolt extractor, simply insert the extractor into the bolt and then turn it counterclockwise. The extractor will grip onto the bolt and remove it.
Assessing the Situation
Before attempting to remove a rounded-off bolt, it’s crucial to thoroughly assess the situation to determine the best approach. Begin by examining the bolt’s condition, assessing the severity of the rounding. If the rounding is minor, you may be able to use a gripping tool, such as a pair of pliers or a bolt extractor, to gain sufficient purchase and remove the bolt. However, if the rounding is more severe, alternative methods, such as drilling or heating, may be necessary.
Next, consider the accessibility of the bolt. If it’s located in a tight or awkward spot, you may need to use specialized tools or modify your approach. Additionally, determine if there are any obstacles or components that may hinder the removal process. If so, you’ll need to take steps to clear the area and ensure a clear path for extraction.
Finally, assess the type of material the bolt is made of. Some materials, such as hardened steel, are more difficult to remove than others. Knowing the material will help you choose the appropriate tools and techniques for the job. Additionally, consider the possibility of damaging surrounding components or the bolt itself during the removal process. If there’s a risk of causing further damage, it may be necessary to consult a professional.
Gather the Necessary Tools
To successfully remove a rounded bolt, you will need to gather the following tools:
Bolt Extractor Set
A bolt extractor set consists of a range of tapered, hardened steel extractors. These extractors are designed to bite into the damaged bolt and provide a secure grip for removal. Choose a set that includes a range of sizes to accommodate varying bolt diameters.
Thread Lubricant
Thread lubricant is essential for reducing friction and allowing the extractor to penetrate the damaged bolt more easily. Apply a penetrating oil or lubricant to the bolt and allow it to soak in before attempting to extract the bolt.
Vice Grip or Pliers
Vice grips or pliers provide a firm hold on the bolt extractor, allowing you to turn it with force. Choose a locking vice grip with a secure grip to ensure it does not slip during extraction.
Hammer
A hammer is used to tap the extractor into the damaged bolt, creating a secure bite. Use a small hammer to avoid damaging the extractor or surrounding materials.
Safety Glasses
Safety glasses are essential to protect your eyes from flying debris during extraction. Wear safety glasses throughout the process to minimize the risk of eye injury.
| Tool | Purpose |
|---|---|
| Bolt Extractor Set | Grabs and extracts rounded bolts |
| Thread Lubricant | Reduces friction and helps extractor bite |
| Vice Grip or Pliers | Holds the extractor firmly during turning |
| Hammer | Taps extractor into damaged bolt |
| Safety Glasses | Protects eyes from flying debris |
Applying Heat
Applying heat to a rounded bolt is a common and effective method for loosening it. The heat expands the metal of the bolt, causing it to loosen its grip on the surrounding material. This can make it much easier to remove the bolt using a wrench or pliers.
To apply heat to a rounded bolt, you will need a heat source such as a blowtorch or a heat gun. If you are using a blowtorch, be sure to hold the flame at least 6 inches away from the bolt to avoid damaging it. If you are using a heat gun, set it to the highest temperature setting.
Once you have heated the bolt for a few minutes, use a wrench or pliers to try to remove it. If the bolt is still too tight, reheat it for a few more minutes and try again.
Applying heat is a relatively safe and effective method for removing rounded bolts. However, it is important to take precautions to avoid damaging the bolt or the surrounding material.
Safety Precautions
When applying heat to a rounded bolt, it is important to take the following safety precautions:
| Safety Precaution |
|---|
| Wear safety glasses and gloves |
| Use a heat source that is appropriate for the size of the bolt |
| Keep the heat source at least 6 inches away from the bolt |
| Be careful not to overheat the bolt or the surrounding material |
Using a Bolt Extractor
A bolt extractor, also known as a screw extractor, is a specialized tool designed to remove damaged or stripped bolts. Here’s a step-by-step guide on how to use a bolt extractor:
- Choose the right size extractor: Bolt extractors come in different sizes, so it’s crucial to select one that is slightly smaller than the damaged bolt. This will ensure a snug fit and prevent the extractor from slipping.
- Drill a pilot hole: Using a drill bit slightly smaller than the bolt extractor, carefully drill a pilot hole in the center of the damaged bolt.
- Tap the extractor into the hole: Insert the bolt extractor into the pilot hole and tap it in firmly using a hammer. Make sure that the extractor is seated deep enough to engage the damaged threads.
- Turn the extractor clockwise: Using a wrench or socket, slowly turn the bolt extractor clockwise. As you apply force, the extractor will bite into the damaged threads and begin to loosen the bolt.
Additional Tips for Using a Bolt Extractor:
- Use plenty of penetrating oil on the damaged bolt before attempting to remove it. This will help to lubricate the threads and reduce friction.
- If the bolt is particularly stubborn, you may need to use a heat gun or torch to heat it up. This will expand the bolt and make it easier to remove.
- Be patient and apply steady pressure when turning the extractor. Avoid using excessive force, as this can damage the extractor or the bolt.
- If the bolt is too badly damaged, it may be necessary to drill it out using a drill bit larger than the bolt. This is a more difficult and time-consuming process, but it may be the only way to remove a severely damaged bolt.
Gripping with Vice Grips
Vice grips are a versatile tool for gripping and turning rounded bolts. They feature a strong, serrated jaw that can bite into the bolt’s surface, providing a secure hold. To use vice grips on a rounded bolt:
1.
Adjust the Jaw
Adjust the jaw width of the vice grips to match the diameter of the bolt. Ensure the jaws are closed tightly enough to provide a good grip but not so tightly as to damage the bolt.
2.
Position the Vice Grips
Position the vice grips on the rounded bolt, ensuring the jaws are aligned with the bolt’s axis. Tighten the locking lever to secure the grips in place.
3.
Twist the Bolt
Using a wrench or pliers, twist the vice grips to loosen the bolt. Apply force gradually, and be careful not to strip the bolt head.
4.
Check the Grip
If the vice grips start to slip, readjust the jaw width or tighten the locking lever. Ensure the vice grips are always positioned correctly to maintain a secure grip on the bolt.
5.
Advanced Gripping Techniques
For particularly stubborn bolts, you may need to employ advanced gripping techniques:
–
|
Technique |
Description |
|
Cross-hatching |
Use a sharp tool to create a cross-hatch pattern on the bolt’s surface, increasing the grip. |
|
Welding |
Weld a small washer or nut onto the bolt head, providing a surface for the vice grips to grip. |
|
Extracting Bolt |
Use a bolt extractor, a specialized tool designed to grip and remove rounded bolts. |
Using a Dremel Tool
If the bolt is still too rounded to grip with pliers, you can try using a Dremel tool. A Dremel tool is a rotary tool that can be used for a variety of tasks, including grinding, cutting, and polishing. To remove a rounded bolt with a Dremel tool, you will need to use a cutting disc.
Step 8: Using a Cutting Disc
To use a cutting disc, follow these steps:
- Put on safety glasses and gloves.
- Attach the cutting disc to the Dremel tool.
- Hold the Dremel tool perpendicular to the bolt.
- Start the Dremel tool and slowly move it back and forth across the bolt.
- Be careful not to cut into the surrounding metal.
- Once the bolt is cut through, you can remove it with a pair of pliers.
If the bolt is too large to fit into the Dremel tool, you can use a larger cutting tool, such as a hacksaw or an angle grinder.
| Tool | Advantages | Disadvantages |
|---|---|---|
| Pliers | Easy to use | Not very effective on rounded bolts |
| Extractor | More effective than pliers | Can be difficult to use |
| Dremel tool | Very effective | Can be dangerous if not used properly |
Welding a New Head
This method involves welding a new hex head onto the stripped bolt. It is a more permanent solution and requires some welding skills and equipment.
9. Steps for Welding a New Head
| Step | Description |
|---|---|
| 1 | Clean the stripped bolt and the surrounding area. |
| 2 | Use a center punch to mark the center of the stripped bolt. |
| 3 | Drill a hole slightly smaller than the diameter of the hex head you will be welding on. |
| 4 | Grind the hole flat and remove any burrs. |
| 5 | Place the new hex head over the hole and secure it with a tack weld. |
| 6 | Weld the new head permanently to the bolt. |
| 7 | Allow the weld to cool completely. |
| 8 | Grind the new head to the desired shape and size. |
| 9 | Use a wrench or socket to remove the bolt. |
Seeking Professional Help
In extreme cases where all other methods have failed, seeking professional assistance may be necessary. Automotive repair shops or locksmiths are equipped with specialized tools and expertise to remove stubborn rounded bolts. They may use techniques such as cutting, drilling, or welding to extract the bolt without damaging the surrounding components.
Before you call in a professional, be sure to provide them with as much information as possible about the situation, including the bolt size, material, and the location of the bolt in the vehicle or machinery.
Here’s a detailed breakdown of what a professional might do to remove a rounded bolt:
| Step | Action |
|---|---|
| 1. Assess the situation | The technician will visually inspect the bolt and surrounding area to determine the best course of action. |
| 2. Gather tools and equipment | Depending on the method chosen, the technician will select the appropriate tools, such as a drill, cutting torch, or welding equipment. |
| 3. Secure the work area | To prevent any accidents, the technician will ensure that the work area is safe and clear. |
| 4. Prepare the bolt | The technician may use a penetrating lubricant or heat to loosen the bolt and make it easier to remove. |
| 5. Access the bolt | If necessary, the technician may need to remove surrounding components to access the bolt more easily. |
| 6. Employ the removal technique | Based on the chosen method, the technician will carefully use the tools to extract the bolt without damaging the surrounding material. |
| 7. Inspect the removed bolt | The technician will examine the removed bolt to identify any underlying issues that may have caused it to become rounded in the first place. |
| 8. Repair the affected area | If any damage occurred during the removal process, the technician will repair the affected area to restore its functionality and prevent future issues. |
| 9. Reassemble the components | Once the bolt is removed and any necessary repairs are made, the technician will reassemble the disassembled components. |
| 10. Test and verify | The technician will thoroughly test the repaired area to ensure that it is functioning properly and that the removed bolt is adequately replaced. |
How To Remove Rounded Bolt
When a bolt head becomes rounded, it can be difficult to remove. However, there are a few methods you can try to get the bolt out.
One method is to use a bolt extractor. Bolt extractors are specially designed tools that grip the rounded head of a bolt and allow you to turn it. To use a bolt extractor, first drill a small hole in the center of the bolt head. Then, insert the bolt extractor into the hole and turn it counterclockwise. The bolt extractor should grip the bolt head and allow you to remove it.
Another method for removing a rounded bolt is to use a pair of pliers. To do this, first grip the bolt head with the pliers. Then, apply pressure to the bolt head and turn it counterclockwise. The pliers should grip the bolt head and allow you to remove it.
If you are unable to remove the rounded bolt using either of these methods, you may need to cut the bolt off. To do this, use a hacksaw to cut through the bolt shank. Once the bolt shank is cut, you should be able to remove the bolt head.
People Also Ask
How do you remove a bolt with a rounded head?
There are a few methods you can try to remove a bolt with a rounded head. One method is to use a bolt extractor. Bolt extractors are specially designed tools that grip the rounded head of a bolt and allow you to turn it. Another method is to use a pair of pliers. To do this, first grip the bolt head with the pliers. Then, apply pressure to the bolt head and turn it counterclockwise. If you are unable to remove the rounded bolt using either of these methods, you may need to cut the bolt off.
What is the best way to remove a rounded bolt?
The best way to remove a rounded bolt depends on the situation. If the bolt is easily accessible, you can try to use a bolt extractor or a pair of pliers. However, if the bolt is difficult to access, you may need to cut the bolt off.
Can you use a drill to remove a rounded bolt?
Yes, you can use a drill to remove a rounded bolt. To do this, first drill a small hole in the center of the bolt head. Then, insert a bolt extractor into the hole and turn it counterclockwise. The bolt extractor should grip the bolt head and allow you to remove it.
