Removing a broken bolt using a welder
Articles, Blog

Removing a broken bolt using a welder

August 13, 2019

often a ball to a store or shear off and you’ll end up we just slightly prowler the surface like that and a lot of times this will be on a machine is something where you can actually get to the back of it so I’ll just rig this up is a bit of a demonstration really there are several techniques for getting a broken bolt out lout but one of the easiest ones and certainly one of the quickest ones is to get a knot of the correct size put that on there and weld the knot on the inside and that likely sticks at a book and stored at a broken bolt and then it’ll help you get it out another important point is you’re far better off doing this with a MIG welder if you’ve got one I’m gonna be using an arc welder here which is a bit more difficult but it’ll still work all the same but it’s just a bit easier with a MIG welder saw this video assumes that you already know how to weld if you don’t know it so well that’ll be coming it alerted err so hopefully so we’re going to put the nuts on there now what we’re gonna do we’re gonna get the welders I actually switched on right now what we’re going to get it we’re just going to all the knots and then we’re just going to tack a bit of a weld on the inside as soon as we’ve got a bit of a weld on we’re going to start running devolved around the inside now an arc weld it’s not ideal for this because it creates a lot of slag which is going to be included in the weld bought for this it doesn’t really matter because all’s we’re concerned about is getting the damage ball to the damage thought outs of that all so what we’re gonna do is we’re just gonna wall that I’m gonna switch the welder on and we’re going to whack a bit of weld in there and till there’s enough well then source a little old and then we can just get our spanner and we can undo it when we remove the block and stored one thing you must do when you’re welding is of course where you correct PPE so I’m now going to put my visor on and you should also ensure that you’ve got adequate ventilation whenever you’re welding so it’s a little bit difficult for me welding here because of the position of the camera and the light but hopefully we’ll be able to get a decent shot of the actual weld going into the actual not so as well as welding something to the top of distort that’ll help as we move it the actually generated during welding is also going to help loosen the stored so it’s important that you get you not exactly over the stud where you want it so we’re now going to switch the welder on and we’ll just run a bit of a weld on the inside of the knot [Music] and you can say that that was actually glowing red out there was that much eating it so that will hopefully help us to remove the stud – I’ll take our spanner should now be able to move to stored and as you can see it has firmly welded and not to the store well as you can see that’s the actual weld on the inside of the knot so that’s one way to remove a broken stud


  • Reply benny bennys November 17, 2011 at 9:53 pm

    How does the weld work,does it just melt the two together?

  • Reply benny bennys November 17, 2011 at 10:31 pm

    Thanks i must get one,look forward to your welding videos.

  • Reply Digadogup November 18, 2011 at 7:58 am

    just a warning for others, do not weld around galvanised metal! its toxic as the zinc fumes are generated!

  • Reply David Urquhart November 21, 2011 at 8:33 am

    Thank you for another great video. I do hope you keep making videos and welding would be a great topic.

  • Reply benny bennys March 28, 2012 at 9:36 am

    will you be doing a welding video soon,thanks.

  • Reply tong pochi June 16, 2012 at 4:40 pm


  • Reply roninx17 September 5, 2012 at 2:27 pm

    Great idea. I was planning on using a welder to get a bolt out, but I couldn't think of what to weld onto it.

  • Reply CuntShovel September 21, 2012 at 2:21 pm

    Bolton accent?

  • Reply Smith2627 September 22, 2012 at 9:35 pm

    I need help mate! I broke one of my 8mm screws in one of my oil filter holes. But it broke off a cm in the hole. What should I do?

  • Reply Joachim Osmundsen September 27, 2012 at 6:05 pm

    In my opinion bolt extractors might be a worse off option. They break so easily, which causes a bigger problem. Use a chiesel and try to hit the bolt in the direction you disassemble it. In theory when the head is off the bolt its not pulling on the threads, which means it should be easy to remove. Try this before you do something more drastic. If you spray in some wd40, and hit the bolt with a hammer and chiesel it might be removable.

  • Reply dddave999 October 8, 2012 at 4:49 pm

    I welded a nut to my cars oil sump plug since (hex socket hole rounded off) it was made of steel and my sump was made of aluminium and they had corroded together (technical name for this escapes me!) I had to weld upside down while under the car, not fun but it worked. Holding the nut in place with a piece of wood just cut to the right length. mig welder was ideal since it allowed for small precise tacks

  • Reply Brad Wright October 14, 2012 at 12:39 pm

    Dissimilar metals can suffer from galvanic corrosion – essentially they set up a small battery with the moisture present and one of the metals gets dissolved and deposited on the other. In the olden days they used to use zinc nails to fasten the copper sheets onto warships – I think this is how they figured it out initially. The saltwater and dissimilar metals caused the hole to increase in size until the plates fell off.

  • Reply dddave999 October 16, 2012 at 7:24 pm

    Galvanic corrosion! I knew there was a technical name for it!!

  • Reply OpenSesame001 October 29, 2012 at 3:13 am

    very good idea… I'm going to try it on my car's cooling fan hood. one bolt broke off and fan is now rattling. thanks for sharing a good tip…

  • Reply enterBJ40 November 4, 2012 at 3:09 am

    sir, you are a genius! wish you were my neighbor…

  • Reply seapeddler November 4, 2012 at 9:32 pm

    I will try this method on the battery terminals.

  • Reply reachforacreech November 10, 2012 at 5:26 pm


  • Reply doyouwanttofuk January 21, 2013 at 8:55 am

    ezy out seams much ezyer to me

  • Reply Connor Burke February 9, 2013 at 6:43 pm

    Your vids are surprisingly enjoying to watch! Subbed!

  • Reply Srk7028 February 12, 2013 at 5:28 pm

    which grade welding electrode u using for this ?

  • Reply Bobby Michael March 19, 2013 at 9:10 pm

    guess youve never broken one.

  • Reply lloydplywood April 26, 2013 at 3:04 am

    Very nicely done.

  • Reply St Pauli May 3, 2013 at 4:57 pm

    using this method is difficult to do because a lot of times you hit the rod on the nut and don't get a good weld;I cover the rod with shrink tube to help as my vision and steadiness have gotten worse over the years.I like the superglue cheat!great advantage

  • Reply cola20845 May 28, 2013 at 12:40 am

    its cool that u can kinda c thought the nut while he's welding

  • Reply doyouwanttofuk June 3, 2013 at 10:15 am

    is this video about removing a bolt with a broken easy out in it?

  • Reply Mike Dinan June 4, 2013 at 9:42 am

    An arc welder? Was this filmed in 1910 ? How did the not brake off in the first place ?

  • Reply Joseph Asturino June 24, 2013 at 3:03 am


  • Reply John Doe July 15, 2013 at 3:15 am

    Great tip once again!

  • Reply PotatoGunsRule August 2, 2013 at 2:32 am

    I need you to come to my house and help me with this old truck I have and a couple of bolts. I wonder if paying your airfare to and from and all your expenses is cost effective? LOL.

    Great video man! Thanks!

  • Reply Dan Kennett August 15, 2013 at 12:00 am

    No, No, No, Weld a flat washer to the broken stud and then weld the nut to the washer. If it is really stuck, also weld the nut hole.

  • Reply khellilg September 11, 2013 at 12:16 am

    2:13 haaaaa cheater!

  • Reply barabaspolo October 15, 2013 at 10:18 pm

    are you really Chuck Norris??


  • Reply Derek Waddell February 23, 2014 at 10:30 am

    yeah but my problem is 4 anti theft locking wheel nuts. where do i put the earth and how do i clean the locking nut without destroying my alloys

  • Reply battleminion February 23, 2014 at 7:59 pm

    Ive be using this metod for many years but i start making some points and clean the slag, one in the top of each other until i have grown a stack of weald at least the heigh of my nut then i make a final weld, that help to prvent th nut of moving and the temperature helps removing the bolt

  • Reply Jeff Gaffney April 30, 2014 at 8:18 pm

    Hi Derek, have you any idea's how to remove on bolt on a motorbike, that's seized solid and the head is stripped, any advice would be most grateful.

  • Reply mikitza1 May 25, 2014 at 10:41 am

    Weld the washer firs and than weld bolt on washer

  • Reply Garry Gemmell April 27, 2015 at 2:25 am

    Excellent i have learned something new today.
    Its a good day!

  • Reply ravengsxr June 20, 2015 at 6:29 am

    Thanks for sharing.    I just bought a 90 amp flux core welder 110vAC. Would this welder be able to do this?

  • Reply Bunroeun Tmorkol September 25, 2015 at 5:23 pm


  • Reply twilson1118 November 29, 2015 at 8:04 am

    theirs nothing bad about arc welders vs mig really. some may call it old fashioned, but its built many bridges, and similar things where sheiding gas is not practical or gets blown away. theirs a rather nice feeling once you take a 7018 rod to something its going to stay put with minimal hassle.

  • Reply Francis Antonio August 7, 2017 at 11:28 pm

    Outstanding !

  • Reply Michael D'Silva September 13, 2017 at 8:43 am

    really well thought out video.. thanks!

  • Reply tubeyourself January 3, 2018 at 5:58 pm

    will a flux core welder do this job?

  • Reply Adrian Ellis April 23, 2018 at 9:45 am

    Great advice

  • Reply snoopy doggy November 6, 2018 at 4:37 am

    Interesting technique. I bet this has saved your hide a few times. I will give this a try with my everlast welder.

  • Reply Gray Anderson December 12, 2018 at 8:27 pm

    Could you not have just drilled it out?

  • Reply Lester Garcia July 17, 2019 at 10:57 pm

    @Ultimate Handyman can this technique also remove a wheel stud that has been overtorqued? my wheel nut has split off from its ball seat base when i used a breaker bar to remove it and now all thats left is the wheel stud & ball seat portion of wheel nut

  • Reply Chris McEvoy July 22, 2019 at 11:16 am

    Can I do this with a Flux welder or will I have issues?

  • Reply GUY Fitzsimmons August 1, 2019 at 9:58 pm

    Put a washer below the nut first to raise the nut up from the surface giving extra clearance from the surface and also protection from weld running out on to the work surface fusing the stud to piece your trying to remove it from defeating the whole object as the molten metal will always take the path of least resistance so if theres any gaps it will find them. Then put the nut on top of the washer then push the welding rod straight down vertically into the centre of the nut onto the broken stud so your penetrating into the top of the stud and then just fill the centre of the washer & nut with weld. Then let it cool right down before trying to undo it as when it cools it will retract /shrink making it even easier to remove. You can also drill down the centre of the broken stud as well to get even better penetration on really stubborn studs and repeat the process as above.

  • Leave a Reply