How To Take Out A Rounded Bolt

Stripped, rounded-off bolts can be a major nuisance. Removing them using traditional methods can be challenging and time-consuming. However, there are effective techniques to tackle this issue with ease. Whether you’re a seasoned mechanic or a DIY enthusiast, understanding how to remove a rounded bolt is crucial for successful repairs and maintenance tasks. By mastering these techniques, you can save valuable time and effort while ensuring that your projects are completed without unnecessary setbacks.

To begin the process of removing a rounded bolt, safety precautions should be taken. Wear appropriate hand protection to prevent injuries. Assess the situation and determine if the bolt is accessible. If not, additional steps may be necessary to create adequate clearance. Next, select the appropriate tools. Vice grips, bolt extractors, and angle grinders are commonly used. Each tool has its advantages and limitations, so choosing the correct one for the specific bolt and situation is essential. Furthermore, having a lubricant like penetrating oil on hand can significantly aid in the removal process.

Depending on the chosen method, the actual removal process may vary. Vice grips provide a firm hold on the bolt, enabling it to be turned out. Bolt extractors are specifically designed to grip and remove damaged bolts. They come in different sizes, so selecting the appropriate extractor for the bolt size is crucial. Angle grinders, on the other hand, are powerful tools that can be used to cut a slot into the bolt, creating a new point of grip. However, caution should be exercised when using angle grinders, as they can generate sparks and heat, posing potential safety hazards. Regardless of the technique employed, patience and precision are key to successful bolt extraction. With the right tools, knowledge, and careful execution, you can overcome the challenge of removing rounded bolts efficiently and effectively.

Identifying the Type of Bolt

A rounded bolt can be frustrating to remove, but the process becomes much easier when you know the exact type of bolt you’re dealing with. Take a moment to examine the bolt and identify its key features:

Head Shape: Bolt heads come in various shapes, including hex, square, button, and fillister. Determining the head shape is crucial as it dictates the type of tool you’ll need to grip the bolt.

Head Shape	Tool Required
Hex	Hex key or socket wrench
Square	Socket wrench
Button	Allen wrench
Fillister	Phillips or slotted screwdriver

Thread Type: Bolts can have different thread types, including coarse, fine, metric, and NPT (National Pipe Thread). Knowing the thread type is important because it determines the pitch and diameter of the bolt, which in turn affects the size of the tools you’ll need.
Material: Bolts can be made of various materials, such as steel, stainless steel, aluminum, and brass. The material of the bolt can influence the techniques you use to remove it.

Once you’ve identified the type of bolt, you can choose the appropriate tools and methods to safely remove the rounded bolt.

Using a Bolt Extractor

Bolt extractors are specialized tools designed to remove rounded-off bolts. They come in various shapes and sizes to accommodate different bolt heads. To use a bolt extractor, follow these steps:

Step 1: Choose the Right Extractor

Select a bolt extractor that is slightly smaller than the bolt head. It should fit snugly into the rounded-off section without damaging the surrounding material.

Step 2: Center the Extractor

Place the extractor over the rounded-off bolt head and center it as much as possible. Use a hammer or a punch to gently tap the extractor into place.

Step 3: Apply Force with a Reverse Drill Bit

Insert a reverse drill bit into the extractor. The reverse drill bit rotates counterclockwise, which is opposite to the direction that the bolt was tightened. Apply force to the drill while slowly turning it counterclockwise. As the extractor bites into the bolt, it will start to loosen. Continue drilling until the bolt is completely removed.

Step 4: Tap the Extractor Out

Once the bolt is loose, tap the extractor out using a hammer and punch. Be careful not to damage the surrounding material.

Here is a table summarizing the steps for using a bolt extractor:

Step	Description
1	Select the right extractor
2	Center the extractor
3	Apply force with a reverse drill bit
4	Tap the extractor out

Applying Heat

Heat can help to loosen the rust and corrosion that may be preventing you from getting a good grip on the bolt. There are a few different ways to heat a bolt, but the most common is to use a heat gun or blowtorch.

Using a Heat Gun

If you’re using a heat gun, hold it about 6 inches away from the bolt and move it around constantly to avoid overheating any one area. Heat the bolt until it’s hot to the touch, but not so hot that you can’t touch it with your bare hands. Keep the heat on for a few minutes, then try to loosen the bolt again.

Using a Blowtorch

If you’re using a blowtorch, be sure to wear gloves and eye protection. Hold the torch about 12 inches away from the bolt and move it around constantly to avoid overheating any one area. Heat the bolt until it’s cherry red, then remove the heat and let it cool for a few minutes. Try to loosen the bolt again while it’s still warm.

Here’s a table summarizing the different methods for applying heat to a rounded bolt:

Method	Temperature	Duration
Heat gun	Hot to the touch	A few minutes
Blowtorch	Cherry red	A few minutes

Drilling and Chiseling

Drilling and chiseling is a more destructive method, but it is effective in removing rounded bolts. This method involves drilling a hole into the center of the bolt and then using a chisel to split the bolt in half. The following steps provide a detailed guide to this method:

Drilling

1. Select a drill bit that is slightly smaller than the diameter of the bolt.

2. Mark the center of the bolt with a center punch or a nail.

3. Place the drill bit on the center mark and start drilling.

4. Drill to a depth of about 1/2 inch into the bolt.

Chiseling

1. Insert a chisel into the hole you drilled.

2. Strike the chisel with a hammer to split the bolt in half.

3. Remove the two halves of the bolt using pliers or a wrench.

Advantages	Disadvantages
Effective in removing rounded bolts	Can damage the surrounding material
Can be used on any type of bolt	Requires a drill and chisel
Relatively inexpensive	Time-consuming

Applying Penetrating Oil

Penetrating oil, also known as penetrating fluid, is a must-have solution for loosening corroded and rusted bolts or nuts. Here’s a detailed guide on how to effectively apply penetrating oil and maximize its efficiency:

1. Safety First

Ensure adequate ventilation and wear gloves to protect your skin from contact with the oil.

2. Locate the Bolt

Identify the rounded bolt that needs to be removed and clean the surrounding area to expose the threads.

3. Penetrating Oil Selection

Choose a high-quality penetrating oil specifically designed for loosening rusted bolts or nuts.

4. Application Techniques

Direct Application: Using a precision nozzle, spray the oil directly onto the bolt threads and let it soak for a few minutes.
Capillary Action: Apply the oil around the edges of the bolt and allow it to wick through the threads by capillary action.
Soaking: For severely rusted bolts, completely submerge them in a penetrating oil bath for extended periods, typically overnight.

5. Waiting Time

Allow the oil to penetrate the threads and break down the rust. The waiting time varies depending on the severity of the rust and the type of penetrating oil used. Consult the product instructions for the recommended waiting period.

6. Repeat Application

For stubborn bolts, multiple applications of penetrating oil may be necessary. Repeat the application and waiting process until the bolt can be loosened.

7. Combination with Heat

Applying heat to the bolt, either with a heat gun or a torch, can enhance the effectiveness of penetrating oil. Heat causes the oil to thin out and penetrate deeper.

8. Patience and Persistence

Breaking loose rounded bolts requires patience and persistence. It may take several applications of penetrating oil and repeated attempts to loosen the bolt. Do not overtighten or force the bolt, as this can cause further damage.

9. Alternative Techniques

If penetrating oil fails to remove the bolt, consider using alternative methods such as bolt extractors, grinding tools, or drilling the bolt head off. However, these techniques should be attempted only by experienced professionals.

Rounding off the head of a bolt is a common problem that can happen to anyone. Fortunately, there are a few simple ways to remove a rounded bolt without damaging the threads.

1. Use a Bolt Extractor

A bolt extractor is a tool that is specifically designed to remove rounded bolts. It is a tapered cone with a left-hand thread. To use a bolt extractor, simply insert the extractor into the rounded bolt and turn it counterclockwise. The left-hand thread will bite into the bolt and remove it.

2. Use Vice Grips

If you don’t have a bolt extractor, you can use a pair of vice grips to remove a rounded bolt. To do this, simply clamp the vice grips onto the bolt and turn it counterclockwise. The vice grips will provide enough grip to remove the bolt.

3. Use a Hammer and Chisel

In some cases, you may need to use a hammer and chisel to remove a rounded bolt. To do this, simply place the chisel on the head of the bolt and tap it with a hammer. The chisel will create a notch in the bolt, which you can then use to turn the bolt with a wrench.