5 Ways To Remove A Rounded Bolt

How To Remove A Rounded Bolt

$title$ Do you have a rounded bolt that you need to remove? If so, you’re not alone. Rounded bolts are a common problem, and they can be frustrating to deal with. However, there are a few things you can do to remove a rounded bolt without damaging it or the surrounding area. In this article, we’ll provide you with a step-by-step guide on how to remove a rounded bolt. We’ll also provide you with some tips on how to prevent rounded bolts from occurring in the future.

If you have a rounded bolt that you need to remove, there are a few things you can do. First, try using a pair of pliers to grip the bolt. If that doesn’t work, you can try using a bolt extractor. These are specially designed tools that can grip rounded bolts and remove them.

If you don’t have a bolt extractor, you can also try using a hammer and chisel. Place the chisel on the side of the bolt and tap it with the hammer. This should create a notch in the bolt that you can use to grip it with a pair of pliers. Once you have a good grip on the bolt, you can remove it by turning it counterclockwise.

Identifying a Rounded Bolt

Distinguishing a rounded bolt from a bolt with slightly worn corners can be challenging, especially if you’re not familiar with the telltale signs. Here’s how to identify a rounded bolt:

**Examine the Head**

Inspect the shape of the bolt head. If the edges appear significantly more rounded than usual, it’s likely rounded.
Look for any visible damage to the head, such as scratches or dents. These can indicate that the bolt was subjected to excessive force or wear.
If the head is too badly rounded to determine its shape, you can use a nut splitter to carefully cut into the head and expose the internal threads.

**Assess Grip**

Try to grip the bolt head with a wrench. If it slips or feels loose, the bolt is probably rounded.
Use a socket or wrench that is slightly smaller than the bolt head. If it fits snugly and doesn’t slip, the bolt is likely not rounded.

**Determine Thread Damage**

If you suspect a rounded bolt, check the threads for damage. Insert a new nut onto the bolt and tighten it by hand.
If the nut threads smoothly without binding or slipping, the threads are likely intact. However, if the nut gets stuck or cross-threads, the threads may be damaged.

**Other Indicators**

Listen for a grinding noise when trying to turn the bolt. A grinding sound often indicates a rounded bolt.
If the bolt head shows signs of being heated, such as discoloration or burn marks, it may have been rounded by excessive force.

Preparation and Safety Measures

Before embarking on the task of removing a rounded bolt, it is crucial to prioritize safety and prepare adequately. Here’s a detailed outline of the necessary steps:

1. Gather the Right Tools

Assemble the necessary tools, including:

Wrenches and sockets of various sizes
Bolt extractors
Hammer
Penetrating oil
Safety glasses
Gloves

2. Prepare the Area

Ensure a safe and well-lit workspace. Clear away any obstructions and work on a stable surface. Wear safety glasses and gloves for protection.

3. Apply Penetrating Oil

Apply penetrating oil liberally to the rounded bolt. Allow it to soak in for several hours or overnight to soften any rust or corrosion.

4. Use Bolt Extractors

Insert the appropriate bolt extractor into the head of the rounded bolt. Using a wrench or socket, gently apply pressure to loosen the bolt counterclockwise. Use a hammer to tap the extractor if necessary, applying force carefully to avoid damaging the bolt or extractor.

If the bolt is particularly stubborn, use a socket that is slightly smaller than the head of the bolt. This will create a tighter fit and increase the gripping power. Alternatively, weld a nut onto the rounded bolt head and use a regular wrench to loosen it.

Situation	Solution
The bolt is too damaged to use bolt extractors	Drill a hole into the bolt head and use a screw extractor
The bolt is flush with the surface	Use a Dremel tool to cut a slot into the head of the bolt
The bolt is seized in place	Apply heat to the bolt using a torch or heat gun

Using a Bolt Extractor

Bolt extractors, also known as screw extractors, are specially designed tools for removing damaged, rounded, or broken bolts. They work by gripping the damaged bolt and turning it out, even when there’s no visible head to grab onto.

Here’s a detailed guide on how to use a bolt extractor:

1. **Choose the right extractor.** Bolt extractors come in a variety of sizes and shapes to fit different bolt sizes. Choose one that’s slightly smaller than the outer diameter of the damaged bolt.

2. **Drill a pilot hole.** Using a drill bit slightly smaller than the extractor, drill a pilot hole into the center of the damaged bolt. This will provide a starting point for the extractor.

3. **Insert the extractor.** Insert the extractor into the pilot hole and turn it counterclockwise using a wrench or socket. The extractor’s teeth will engage with the damaged bolt and begin to bite into it.

4. **Apply downward pressure.** As you turn the extractor, apply firm downward pressure to maintain contact between the extractor and the bolt. This will help prevent the extractor from slipping and damaging the bolt further.

5. **Continue turning.** Continue turning the extractor counterclockwise until the damaged bolt loosens and can be removed by hand.

6. **Clear the hole.** Once the bolt is removed, use a tap to clear any remaining threads or debris from the hole.

Additional Tips for Using a Bolt Extractor

Use a high-quality extractor from a reputable manufacturer.
If the extractor isn’t gripping the bolt properly, try using a piercing tap to create a sharper grip.
If the bolt is particularly stubborn, apply some penetrating lubricant to help loosen it.
Take your time and apply constant pressure to avoid breaking the extractor.

Drilling and Tapping Method

The drilling and tapping method involves drilling a hole in the center of the rounded bolt and then tapping it to create threads for a new bolt. This method is more complex than the other methods but it is also the most effective.

Steps:

1. Drill a pilot hole. Use a drill bit that is slightly smaller than the diameter of the bolt. Drill the hole in the center of the bolt, being careful not to drill too deep.
2. Tap the hole. Use a tap that is the same size as the bolt you want to use. Tap the hole by turning the tap clockwise. Be careful not to over-tap the hole.
3. Screw in the new bolt. Use a bolt that is the same size as the tap you used. Screw the bolt into the hole by turning it clockwise.
4. Heat the rounded bolt and use a chisel. If the bolt is heavily rusted, you may need to heat it first to loosen it. Apply heat with a propane torch or other heat source, being careful not to overheat the bolt. Once the bolt is heated, use a chisel to break it free.

Pros	Cons
Most effective method	Complex and requires specialized tools
Can be used on bolts of any size	Can damage the surrounding area

Angle Grinder Technique

If you have access to an angle grinder, you can cut a slot into the head of the bolt. Once you’ve created a deep enough slot, you should be able to use a flathead screwdriver to turn the bolt out.

Materials you’ll need:

Angle grinder
Cutting disc
Flathead screwdriver

Steps:

Put on safety gear. Wear eye protection, gloves, and earplugs when using an angle grinder.
Secure the workpiece. Clamp the workpiece in a vise or on a stable surface.
Cut a slot into the bolt head. Use a cutting disc to cut a slot into the head of the bolt. The slot should be deep enough to reach the threads of the bolt.
Insert a flathead screwdriver into the slot. Insert a flathead screwdriver into the slot and turn the screwdriver to loosen the bolt.
Inspect the bolt. Once the bolt is loose, inspect it for damage. If the threads are damaged, you will need to replace the bolt.

Tips:

Use a cutting disc that is the same size or slightly smaller than the diameter of the bolt.
Hold the angle grinder firmly and cut slowly and carefully.
If the bolt is very tight, you may need to cut multiple slots into the head of the bolt.

Vice Grip with a Pipe or Wrench

If you have a little more room to work with, you can try using a vice grip and a pipe or wrench. First, grip the rounded bolt head with the vice grip. Then, place the end of the pipe or wrench over the vice grip handle. This will give you a longer lever to apply more force to the bolt.

Step 1: Use a file to make two flats on the bolt head.

This will give you a better grip with the vice grip.

Step 2: Place the vice grip on the bolt head and tighten it down.

Make sure that the vice grip is securely fastened to the bolt head.

Step 3: Place the pipe or wrench over the vice grip handle and pull.

Apply steady pressure to the wrench until the bolt loosens. If the bolt is particularly stubborn, you may need to use a cheater bar to get more leverage.

Step 4: Once the bolt is loose, remove it by hand.

Be careful not to drop the bolt!

Easy-Out or Screw Extractor Tool

An easy-out or screw extractor tool is a specialized tool designed to remove broken or damaged screws, bolts, or studs. It typically consists of a tapered, spiral-shaped body with a hardened steel tip. The tool is inserted into the damaged fastener and turned counterclockwise to engage the spiral threads with the damaged threads of the fastener. As the tool is turned, it bites into the damaged threads and generates enough force to extract the fastener.

Easy-out tools come in various sizes and styles, depending on the size and type of fastener being removed. The process of using an easy-out tool involves the following steps:

Select an easy-out tool that is the appropriate size for the damaged fastener.
Drill a small pilot hole into the center of the damaged fastener. The pilot hole should be deep enough to accommodate the tip of the easy-out tool.
Insert the easy-out tool into the pilot hole and engage the spiral threads with the damaged threads of the fastener.
Gently tap the easy-out tool with a hammer to seat it properly in the fastener.
Turn the easy-out tool counterclockwise using a wrench or pliers.
Continue turning the easy-out tool until the fastener is removed.
If the fastener is particularly stubborn, apply penetrating oil or lubricant to the damaged threads to help loosen it.

Liquid Wrench

Liquid Wrench is a penetrating oil that helps to loosen rusted or seized bolts. To use Liquid Wrench, simply spray it onto the bolt and let it sit for a few minutes. The oil will penetrate the threads of the bolt and help to break down the rust or corrosion that is holding it in place. Once the bolt has been loosened, you can then remove it using a wrench.

Heat Application

Heat can also be used to loosen a rounded bolt. To do this, simply heat the bolt with a torch or heat gun until it is red hot. Once the bolt is hot, you can then use a wrench to remove it. Be careful not to overheat the bolt, as this can damage the threads.

Additional Tips for Removing a Rounded Bolt

In addition to using Liquid Wrench and heat, there are a few other things you can try to remove a rounded bolt. These include:

Using a bolt extractor. A bolt extractor is a tool that is designed to grip onto the rounded head of a bolt and turn it out.
Using a hammer and chisel. If the bolt is not too large, you can try to use a hammer and chisel to break the head off of the bolt. Once the head is off, you can then use pliers to remove the rest of the bolt.
Drilling out the bolt. If all else fails, you can try to drill out the bolt. To do this, simply drill a hole into the center of the bolt and then use a tap to thread the hole. Once the hole is tapped, you can then use a bolt extractor to remove the bolt.

Hammer and Chisel Strategy

This method requires a hammer and a chisel. Place the chisel’s tip against the rounded bolt head and strike it with the hammer. The chisel will create a groove in the bolt head, which can then be used to turn the bolt with a wrench.

9. Using a Hacksaw

If the other methods have failed, you can resort to using a hacksaw. Place the hacksaw blade against the bolt head and cut a groove into it. Once the groove is deep enough, you can use a screwdriver or a wrench to turn the bolt. Be careful not to cut into the surface around the bolt.

Pros	Cons
Effective for badly rounded bolts	Time-consuming
Low cost	Requires precise hand-eye coordination

Replacement Bolt Selection

When choosing a replacement bolt, it’s crucial to prioritize the following factors:

Size and Thread Pitch

Ensure the replacement bolt matches the original in diameter, length, and thread pitch. If necessary, use a thread gauge to determine the correct thread pattern.

Material

Select a bolt made from a similar material to the original. Common materials include steel, stainless steel, and galvanized steel. Consider the application’s specific requirements, such as corrosion resistance or strength.

Strength

Verify the strength of the replacement bolt meets or exceeds the original. Check for markings indicating the bolt’s grade or strength designation.

Head Style

Choose a bolt with a head style that matches the original. Common head styles include hex, flat, button, and countersunk. Ensure the head size fits the available space and allows for proper tightening.

Finish

Consider the finish of the replacement bolt. Options include plain, zinc-plated, or hot-dipped galvanized. Select a finish that suits the application’s aesthetic and protective needs.

How to Remove a Rounded Bolt

A rounded bolt can be a frustrating problem to deal with, but it can be resolved with the right tools and techniques. Here’s a step-by-step guide to help you remove a rounded bolt effectively:

Use a bolt extractor: This specialized tool is designed to grip and remove rounded bolts. Select an extractor that matches the bolt size and insert it into the bolt head. Turn the extractor counterclockwise with a wrench or socket to loosen the bolt.
Weld a nut to the bolt: If the bolt head is severely rounded, you can weld a nut onto it. After the weld has cooled, use a wrench to turn the nut and remove the bolt.
Use a hammer and chisel: Position the chisel against the bolt head and tap it with a hammer. The impact should create slots into which you can insert a screwdriver or wrench to turn the bolt.
Use penetrating oil: Apply penetrating oil to the rounded bolt and let it sit for several minutes. The oil will help to loosen the bolt and make it easier to remove.
Use vice grips: If you can’t get a good grip on the bolt with regular tools, try using vice grips. Clamp the vice grips onto the bolt and turn it counterclockwise to loosen it.