How To Remove Snap Bolts

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Snap bolts, also known as one-way bolts or expansion bolts, are designed to provide a secure, permanent connection between two pieces of material. However, there may come a time when you need to remove a snap bolt, whether it’s due to a change in plans, a repair, or simply a desire to reuse the bolt. Removing snap bolts can be challenging due to their one-way design, but it is possible with the right tools and techniques. In this article, we will guide you through the step-by-step process of how to remove snap bolts safely and effectively. We will cover the necessary tools, safety precautions, and common challenges you may encounter along the way.

Before attempting to remove a snap bolt, it’s crucial to gather the necessary tools. The most important tool is a pair of snap bolt pliers, which are specifically designed to grip and remove snap bolts. Additionally, you may need a hammer, chisel, and safety glasses. Always wear safety glasses when working with tools to protect your eyes from flying debris. Once you have the necessary tools, you can begin the removal process.

Identifying Snap Bolts

Snap bolts, also known as mushroom anchors or toggle bolts, are a versatile type of fastener commonly used in construction and engineering applications. These bolts are designed to be installed through a hole in the material being secured and then expanded to create a secure hold. Snap bolts are particularly effective for anchoring objects to hollow or thin surfaces where traditional bolts or screws may not be feasible.

Key Features of Snap Bolts:

1. **Spring-Loaded Toggle Wings**: The most distinctive feature of snap bolts is their spring-loaded toggle wings. These wings are designed to fold flat when the bolt is inserted through the hole. Once the bolt is tightened, the toggle wings unfold and lock against the back of the surface, providing a strong and reliable anchor point.

Spring-Loaded Toggle Wings	Image	Description
Folded Wings	[Image of folded toggle wings]	Toggle wings folded flat for insertion through the hole.
Unfolded Wings	[Image of unfolded toggle wings]	Toggle wings expanded and locked against the back of the surface.

2. **Unique Bolt Shank**: Snap bolts have a unique bolt shank that is slightly tapered toward the end. This tapered shank allows for easy insertion through the hole and helps to spread the load of the anchor when tightened.
3. **Hexagonal or Mushroom Head**: Snap bolts typically have either a hexagonal or mushroom-shaped head. The hexagonal head provides a convenient grip for tightening the bolt, while the mushroom head prevents the bolt from being pulled through the hole.

Removing Snap Bolts with a Pry Bar

Using a pry bar is a common and effective method for removing snap bolts. This technique is particularly useful when the bolt is heavily rusted or otherwise difficult to remove. To use a pry bar to remove a snap bolt, follow these steps:

Position the tip of the pry bar on the side of the bolt, near the base.
Gently tap the pry bar with a hammer until it is firmly wedged under the bolt.
Apply pressure to the pry bar by pushing down on the opposite side.
As the bolt begins to loosen, continue to apply pressure until it is completely removed.

If the bolt is particularly stubborn, it may be necessary to heat it with a torch before attempting to remove it with a pry bar.

Pros	Cons
Effective method for removing rusted or stuck bolts	Can be difficult to wedge the pry bar under the bolt
Relatively simple and inexpensive technique	May damage the surrounding area if not used carefully
Can be used in tight spaces	Time-consuming for removing multiple bolts

Using a Bolt Extractor for Snap Bolt Removal

A bolt extractor is a specialized tool designed to remove broken or damaged bolts, including snap bolts. It consists of a hardened steel body with a tapered end and a reverse-threaded screw. The tapered end fits into the damaged bolt while the reverse-threaded screw engages with the broken bolt’s threads. As you turn the extractor counterclockwise, it bites into the bolt’s threads and loosens it for removal.

To use a bolt extractor for snap bolt removal, follow these steps:

Select the correct size extractor based on the size of the snap bolt.
Center the extractor over the damaged bolt and tap it gently to insert the tapered end into the bolt’s hole.
Use a wrench or a socket to turn the extractor counterclockwise. As you turn, the reverse-threaded screw will dig into the bolt’s threads, gradually loosening it.
Once the bolt is loose, gently pull it out of the hole using pliers or a bolt grip.

Here are some additional tips for using a bolt extractor:

Tip	Description
Use a sharp extractor	A dull extractor will not bite into the bolt’s threads effectively.
Lubricate the extractor	Applying a lubricant to the extractor will help it bite into the bolt’s threads more easily.
Apply pressure evenly	Do not apply excessive force to the extractor. Instead, use a steady and even pressure to loosen the bolt.

Utilizing a Nut Splitter for Difficult Snap Bolts

Nut splitters are specifically designed to remove damaged or seized nuts and bolts, including snap bolts. Here’s a detailed guide on how to use a nut splitter for difficult snap bolts:

1. Select the Correct Nut Splitter

Choose a nut splitter that is slightly larger than the nut size of the snap bolt. The nut splitter should have sharp blades to make a precise and clean cut.

2. Position the Nut Splitter

Place the nut splitter over the nut of the snap bolt. Ensure that the blades are aligned with the sides of the nut. Tighten the nut splitter until it firmly grips the nut.

3. Drive the Wedge

Using a hammer or mallet, strike the wedge of the nut splitter sharply. The wedge will force the blades outward, splitting the nut into two halves.

4. Remove the Nut Halves

Once the nut is split, carefully remove the two halves using a pair of pliers or a punch. If the halves are stuck, you can twist them slightly while pulling them out. In some cases, you may need to use penetrating lubricant to loosen the connection.

Tip	Description
Lubricate the nut	Penetrating lubricant can help loosen a seized nut. Apply it to the nut threads and let it penetrate before using the nut splitter.
Use a sharp wedge	A sharp wedge will make a clean cut, preventing damage to the snap bolt.
Protect your eyes	Wear safety glasses while using a nut splitter, as fragments of the nut may fly off during the splitting process.

Employing Angle Grinder for Stubborn Snap Bolts

In scenarios where other techniques fail to yield results, employing an angle grinder might become necessary. This power tool is capable of slicing through even the most resilient snap bolts, offering a potent solution for removing stubborn bolts.

Donning Safety Gear

Prioritize safety by wearing appropriate protective gear, including safety glasses, gloves, and earplugs, to minimize potential risks during the process.
Choosing the Right Cutting Disc

Select a metal-cutting disc compatible with the angle grinder and suitable for the specific material of the snap bolt. Ensure the disc is securely attached before proceeding.
Positioning the Grinder

Position the angle grinder perpendicular to the surface of the snap bolt and maintain a firm grip on the tool. Ensure steady control to prevent any accidental slippage.
Making Gradual Cuts

Commence cutting the bolt gradually, applying moderate pressure and moving the grinder slowly to avoid overheating or damaging the surrounding area.
Utilizing a Cutting Guide (Optional)

For added precision, consider utilizing a cutting guide or template to ensure straight cuts. This is particularly useful when working in confined spaces or dealing with intricately shaped snap bolts.

Inspecting the Bolt

Monitor the cutting progress and inspect the bolt periodically. As the cut deepens, the bolt may begin to loosen. In such cases, discontinue grinding and attempt to remove the bolt manually.

By following these steps and exercising caution throughout the process, you can effectively remove stubborn snap bolts using an angle grinder.

Drilling Out Damaged or Broken Snap Bolts

Drilling out damaged or broken snap bolts is a more challenging process, but it can be successful with the right tools and techniques. Here are detailed steps to guide you through the process:

Step 1: Safety First

Wear appropriate safety gear, including gloves, safety glasses, and a dust mask. Snap bolts can shatter, so use caution during drilling.

Step 2: Mark the Center

Using a center punch, mark the exact center of the snap bolt head.

Step 3: Choose the Right Drill Bit

Select a drill bit slightly smaller than the outer diameter of the snap bolt. The drill bit should be made of high-speed steel or carbide.

Step 4: Drill Carefully

Start by drilling a small pilot hole. Gradually increase the drill bit size until you reach the full diameter of the snap bolt. Maintain a steady drilling speed and ensure the bit remains perpendicular to the bolt.

Step 5: Remove the Bolt

Once the bolt is drilled out, use a bolt extractor to remove the remaining fragments. The extractor should be slightly smaller than the hole you drilled.

Step 6: Advanced Techniques for Stubborn Bolts

If the bolt is severely damaged or rusted, you may need to employ advanced techniques:

Weld a Nut: Weld a large nut onto the exposed bolt head. This provides a handle for twisting the bolt out.
Heat the Bolt: Heat the bolt with a propane torch to weaken the rust and allow for easier drilling.
Use a Dremel Tool: Grind down the snap bolt head using a Dremel tool with a cut-off wheel. Be cautious and wear proper safety gear when using this method.

Step 7: Clean Up

After removing the snap bolt, clean the area thoroughly to remove any metal shavings or debris.

Removing Snap Bolts with a Vise Grip

If you don’t have access to a wrench or a bolt remover, you can use a vise grip to remove a snap bolt. Here’s how:

Step 1: Gather Materials

You will need a vise grip and a pair of pliers.

Step 2: Open the Vise Grip

Open the jaws of the vise grip wide enough to fit around the head of the snap bolt.

Step 3: Position the Vise Grip

Position the vise grip around the head of the snap bolt, making sure that the jaws are gripping the bolt securely.

Step 4: Tighten the Vise Grip

Tighten the vise grip until it is securely gripping the bolt. Do not overtighten the vise grip, as this can damage the bolt.

Step 5: Twist the Vise Grip

Twist the vise grip back and forth to loosen the snap bolt. Do not use too much force, as this can strip the bolt.

Step 6: Remove the Vise Grip

Once the snap bolt is loose, remove the vise grip and pull the bolt out of the hole.

Step 7: Inspect the Bolt

Inspect the snap bolt for damage. If the bolt is damaged, it should be replaced.

Possible Damage	Action
Stripped threads	Replace the bolt
Bent or damaged head	Replace the bolt
Broken bolt	Remove the broken bolt using a bolt extractor

Preventing Future Snap Bolt Problems

1. Use the Correct Size Bolts

Using the correct size bolts for your application is crucial. Bolts that are too small will not be able to handle the load and may snap, while bolts that are too large may damage the material you are attaching.

2. Tighten Bolts to the Correct Torque

Tightening bolts to the correct torque is also important. Bolts that are too loose may not be able to hold the load securely, while bolts that are overtightened may snap.

3. Use Washers

Washers can help to distribute the load on the bolt and prevent the material from being damaged. They can also help to prevent the bolt from loosening.

4. Use Lock Nuts

Lock nuts can help to prevent bolts from loosening and coming undone. They are especially useful in applications where there is a lot of vibration.

5. Inspect Bolts Regularly

Inspecting bolts regularly can help to identify any problems early on before they become serious. Look for signs of corrosion, damage, or wear.

6. Replace Bolts if Necessary

If you find a bolt that is damaged or excessively worn, replace it immediately. Do not try to repair a damaged bolt, as it may not be able to handle the load.

7. Thread Lock

Thread lock can help to prevent bolts from loosening and coming undone. It is a liquid that is applied to the threads of the bolt before it is tightened.

8. Galvanized Steel

Galvanized steel is more resistant to corrosion than regular steel. Using galvanized steel bolts in outdoor applications can help to prevent them from rusting and snapping.

Material	Tensile Strength (psi)
Steel	58,000 – 150,000
Stainless Steel	75,000 – 130,000
Aluminum	13,000 – 50,000
Titanium	83,000 – 128,000

Safety Considerations for Snap Bolt Removal

Prioritize safety by adhering to these crucial precautions before embarking on the removal process:

9. Be Mindful of Surrounding Structures

Exercise utmost caution when working in confined spaces or near delicate structures. Assess potential hazards thoroughly before proceeding to prevent damage to yourself or the environment. Wear appropriate personal protective equipment (PPE), such as gloves and safety glasses. Ensure ample ventilation to avoid breathing in harmful fumes. If possible, create a temporary barrier around the area to prevent debris from flying out and causing injuries.

Remain aware of the potential for electrical hazards if working near power lines or machinery. If there is any doubt about potential risks, promptly contact a qualified electrician or safety professional for assistance. Be mindful of the possibility of sharp edges or broken pieces of metal that may cause injury. Use caution to prevent slipping or tripping on uneven surfaces or debris.

If the snap bolt is located in a challenging or dangerous position, refrain from attempting the removal process on your own. Instead, seek professional assistance from a qualified mechanic or structural engineer to ensure safety and prevent any further damage.

Choosing the Right Tool for the Job

Selecting the appropriate tool for removing snap bolts is crucial for efficiency and safety. Different tools are designed for specific types of snap bolts and materials. Here’s a detailed guide to help you choose the right tool for the job.

1. Pliers

Suitable for small snap bolts with exposed heads, regular pliers provide a simple method of removal. Needle-nose pliers offer increased precision for smaller bolts or tight spaces.

2. Long-Nose Pliers

Similar to regular pliers, long-nose pliers have extended jaws that allow access to hard-to-reach bolts in confined areas.

3. Slip Joint Pliers

Versatile and adjustable, slip joint pliers can accommodate various bolt sizes, providing a secure grip for removal.

4. Mole Grips

Also known as locking pliers, mole grips lock onto the bolt, offering a tight grip even on rounded or damaged bolts.

5. Socket Wrench

Paired with the appropriate socket size, a socket wrench provides a powerful and controlled method for removing larger snap bolts with exposed heads.

6. Allen Key

Designed for bolts with hexagonal heads, an Allen key fits directly into the bolt’s socket and provides leverage for removal.

7. Torx Key

Similar to an Allen key, a Torx key is designed specifically for bolts with star-shaped heads, offering a secure and non-slip grip.

8. Snap Bolt Removal Tool

Specialized snap bolt removal tools are designed to extract snap bolts with concealed heads. These tools typically feature a tapered hook or extractor that engages the bolt’s hole.

9. Bolt Extractor

Bolt extractors have a reverse-threaded design that drills into the bolt and grabs onto its threads, allowing for removal even when the bolt’s head is damaged or broken.

10. Impact Driver

Impact drivers deliver high-torque impulses that can loosen stubborn or seized snap bolts. However, their use requires caution to avoid damaging the surrounding material.

Bolt Type	Recommended Tools
Exposed Head Snap Bolts	Pliers, Long-Nose Pliers, Socket Wrench, Allen Key, Torx Key
Concealed Head Snap Bolts	Snap Bolt Removal Tool, Bolt Extractor
Stubborn or Seized Snap Bolts	Impact Driver