How to remove rusted bolts (and other sticky situations)

October 28, 2024
By CRC Industries, for the Blue Print

Stuck or rusted bolts can be a nightmare for anyone attempting repairs or maintenance tasks. They can slow progress, cause frustration, and even lead to damaged equipment or components if not handled properly. However, knowing how to remove rusted bolts with the right techniques and tools, loosening these stubborn bolts can become a manageable task.

Before jumping right into dealing with those stuck bolts, it's good to understand why they get stuck or rusted in the first place. Exposure to moisture, corrosion, overtightening, or prolonged periods of inactivity can all contribute to the issue. Recognizing these causes helps in selecting the most appropriate approach to address the problem.

Here are some effective methods to tackle stuck or rusted bolts:
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Preparation

When dealing with rusted or stuck bolts, proper preparation is key to success. Taking the right precautions and using effective techniques will help ensure you can safely and efficiently remove the bolts without causing damage to surrounding materials. Follow these steps to get started and set yourself up for the best chance of success.

1. Safety First: Before trying to loosen stuck bolts, make sure to wear safety goggles and gloves. This will protect you from hazards such as flying debris or sharp edges.
2. Penetrating Oil: Begin by applying a high-quality penetrating oil to the stuck bolt. Allow sufficient time for the oil to seep into the threads and break down rust or corrosion.
3. ​Heat Application: If the penetrating oil alone doesn't do the trick, heat can be a valuable ally. Use a propane torch or heat gun to gently heat the surrounding area of the bolt. Thermal expansion can help loosen the bond between the bolt and the material it's threaded into.
4. Cold Application: Heat isn't the only option for using temperature on a stuck bolt situation. Freezing penetrant spray works by quickly lowering the temperature. This rapid drop helps loosen stuck or rusted bolts, nuts, and joints in just a few seconds after applying.
5. Mechanical Assistance: For extremely stubborn bolts, mechanical assistance may be necessary. Tools such as impact wrenches or breaker bars can provide the extra torque needed to break free seized bolts.

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Techniques for loosening stuck bolts

Once you've taken the necessary preparation steps, it's time to apply specific techniques to loosen the stuck or rusted bolts. Different methods work better depending on the situation, so it’s important to have a range of options. Below are some effective techniques that can help break even the most stubborn bolts free.

1. Reverse and Rock: Sometimes, just switching between tightening and loosening the bolt can help break the rust or corrosion that is holding it in place. Gradually increase the force while rocking the bolt back and forth until it begins to loosen.
2. Impact Options: Impact drivers or wrenches give quick, powerful bursts of force to the bolt. This makes them good at breaking stubborn bolts free. Apply steady pressure while striking the bolt head to deliver sharp impacts.
3. Cheater Bar Method: For added leverage, use a length of pipe or a "cheater bar" over the handle of a wrench or breaker bar. This extended leverage can multiply the force applied, making it easier to loosen tight bolts. When using this method, be sure to exercise caution. A cheater bar gives you extra force to loosen a stuck bolt. However, it also increases the risk of damaging the bolt, the tool, or causing injury.
4. Nut Splitter or Bolt Extractor: In cases where the bolt head is damaged or inaccessible, nut splitters or bolt extractors can be great options. These specialized tools grip onto the bolt or nut, allowing it to be twisted out even when the head is rounded or stripped.

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Post-loosening care

Once the bolt is successfully loosened, it's essential to clean the threads and surrounding area thoroughly. Remove any remaining rust or debris using a wire brush or abrasive pad.
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When loosening just isn't an option

Knowing when to cut off, drill out or forcibly extract a rusted bolt rather than continuing to try to loosen it can save time and prevent frustration. Here are some indicators that it might be time to give up on trying to salvage a rusted bolt and pursue other options:
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1. Severe Corrosion: If the bolt is heavily rusted and corroded, the head or threads may be badly damaged. In this case, trying to loosen it could cause more harm than good.
2. Broken or Rounded Head: If the bolt head is already damaged, rounded off, or partially broken, it may be difficult or impossible to grip with conventional tools. In such cases, cutting off the bolt may be the most practical solution.
3. Limited Access: If the bolt is in a tight space, it can be hard to use enough force to loosen it. In this situation, cutting it off might be easier than trying to use tools in such a confined area.
4. Time Constraints: If you're working on a time-sensitive project, spending excessive time trying to loosen a rusted bolt may slow progress. Cutting it off and replacing it with a new bolt may be the quickest solution.
5. Repeated Failed Attempts: If you've tried several methods to loosen the bolt, like using penetrating oil, heat, or impact tools, and none have worked, it may be a sign the bolt is too damaged. In this case, cutting it off might be the best solution.
6. Safety Concerns: If trying to loosen the bolt could damage nearby parts or create safety risks, it's safer to stop. Cutting off the bolt is a better option to prevent accidents or injuries.

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Alternatives to loosening stuck bolts

When faced with a rusted or stuck bolt, traditional methods like applying penetrating oil or using a wrench may not always work. In such cases, alternative methods are necessary to remove the bolt without causing damage to the surrounding area or the components involved. As with any procedure involving shop tools, the use of safety glasses, gloves, and other applicable protective equipment is highly recommended.
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1) Cutting the Bolt: When traditional methods fail, cutting the bolt may be the quickest and most effective solution. This approach works especially well for bolts that are heavily rusted or in hard-to-reach areas. With the right tools, you can remove the bolt without damaging the surrounding materials.
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Tools Required:

• Angle grinder or rotary tool with a cutting disc (or a hacksaw)
• Lubricant or penetrating oil
• Cold chisel
• Hammer

Procedure:

1. Apply a penetrant to help loosen the rust and make the bolt easier to cut.
2. Choose your cutting tool. Angle grinders or rotary tools are ideal for bolts that are difficult to access or in confined spaces. A hacksaw works best for small or easily accessible bolts.
3. Cutting the bolt off with an angle grinder or rotary tool:
   • Position the cutting disc perpendicular to the bolt.
   • Turn on the tool and carefully guide the cutting disc through the bolt head. Apply steady pressure, but do not force the tool.
   • Continue cutting until the head of the bolt is completely removed.
4. Cutting the bolt off with a hacksaw:
   • Secure the bolt or workpiece to prevent movement.
   • Use steady, even strokes to saw through the bolt.
   • Patience is key to maintaining control and accuracy.
   • Continue cutting until the bolt head is removed.
5. Once the head is removed, you can often slide out the remaining shaft of the bolt from the assembly. If the shaft is still stuck, proceed with additional methods:
   • Use a cold chisel and hammer to break the remaining bolt shaft into smaller pieces. This method requires caution to avoid damaging the surrounding material.
   • Use a flathead screwdriver or pry bar to gently pry out the remaining bolt shaft. Tap the end with a hammer if necessary to loosen it further.

2) Drilling and Tapping: If cutting the bolt isn't an option, drilling and tapping is another effective method. By creating a new threaded hole, you can remove the damaged bolt and replace it with a new one. This technique requires precision but is a reliable solution when dealing with stubborn bolts.

Tools Required:

• Drill
• Drill bits
• Tap set
• Center punch
• Hammer
• Small brush
• Lubricant (such as cutting oil)

Procedure:

1. Use a center punch and hammer to create a small indentation in the center of the bolt head. This helps guide the drill bit and prevents it from wandering.
2. Start with a small drill bit (Ex. 1/8”) and drill a pilot hole through the center of the bolt, using steady pressure and ensuring the hole is straight.
3. Increase the size of the drill bits and continue drilling until reaching the recommended size of the tap you will use.
4. Apply cutting oil to the hole when increasing drill bit size to reduce friction and heat buildup. 
5. Insert a tap that matches the original bolt size to create new threads in the hole.
6. Apply more cutting oil to the drilled hole.
7. Turn the tap clockwise a quarter turn, then back it off slightly to clear the threads and remove metal shavings. Repeat this process until the tap is fully through the hole.
8. Once the new threads are cut, carefully remove the tap by turning it counterclockwise.
9. Clean the newly tapped hole with compressed air or a brush to remove any remaining metal shavings.
10. Insert new bolt into the freshly tapped hole.

3) Using a Bolt Extractor Set: A bolt extractor set is a specialized tool designed for situations where the bolt head is damaged or inaccessible. This method allows you to grip and remove the bolt even when other tools can't. It's a precise and effective way to deal with bolts that have stripped heads.

Tools Required:

• Bolt extractor set
• Drill
• Drill bits
• Center punch
• Hammer
• Adjustable wrench
• Lubricant (such as cutting oil)
• Small brush

Procedure:

1. Use a center punch and hammer to create a small indentation in the center of the bolt head. This helps guide the drill bit and prevents it from wandering.
2. Select a drill bit slightly smaller than the diameter of the bolt extractor and drill a pilot hole through the center of the bolt, using steady pressure and ensuring the hole is straight.
3. Periodically withdraw the drill bit to remove metal shavings and apply cutting oil to the hole.
4. Choose the correct size extractor from the bolt extractor set. The extractor should fit snugly into the pilot hole.
5. Gently tap the extractor into the pilot hole with a hammer until it is securely seated. The extractor's reverse threads will bite into the bolt as it is turned.
6. Attach an adjustable wrench or T-handle wrench to the end of the extractor. Turn the wrench counterclockwise slowly and steadily. As you turn, the extractor will grip the bolt more tightly and begin to loosen it. Continue turning until the bolt is fully extracted from the hole.
7. After removing the bolt, clean the threaded hole with compressed air or a brush to remove any remaining metal shavings or debris.

4) Welding a Nut to the Bolt: For bolts that are severely stuck, welding a nut to the bolt can provide the extra leverage needed to remove it. This technique involves attaching a nut to the bolt and then using the nut to turn and loosen the bolt. It’s especially useful when the bolt head is damaged or rounded off.

Tools Required:

• Welding machine
• Welding helmet and protective clothing
• Nut (slightly larger than the bolt diameter)
• Wrench or socket set
• Wire brush or grinder
• Heat-resistant gloves
• Penetrating oil

Procedure:

1. Clean the area around the bolt using a wire brush or grinder. Remove any rust, paint, or debris to ensure a good weld.
2. Apply penetrating oil to the bolt and let it sit for a few minutes to help loosen any rust or corrosion.
3. Select a nut that is slightly larger than the bolt diameter and place it over the end of the bolt, ensuring it is centered and stable.
4. Begin welding by attaching the ground clamp to a suitable metal surface. Start the weld on the inside edge of the nut, making sure to fill the center and weld around the circumference of the nut. This ensures a strong connection between the nut and the bolt.
5. Allow the weld to cool for a minute or two. This can help break the bond of the rust by causing thermal contraction.
6. Attach an appropriately sized wrench or socket to the welded nut and apply steady, even pressure to turn the nut counterclockwise. The welded nut should provide the leverage needed to loosen and remove the bolt.
7. If the bolt does not move initially, try gently tapping the wrench with a hammer to provide a shock that can help break the rust bond.
8. Once the bolt is removed, clean the threaded hole with a wire brush or compressed air to remove any remaining debris or metal shavings.

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Conclusion

Removing a rusted or stuck bolt can be challenging. There are several good options to choose from. The best method depends on the situation, the tools you have, and your skill level. You might loosen a bolt, cut it, drill and tap, use a bolt extractor set, or weld a nut. Each technique has its own advantages and possible drawbacks. Understanding these methods will help you tackle even the most stubborn bolts with confidence.
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​Content originally from CRC Industries. Reused here with permission.

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