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Welded new metal on top broken rusted bolts to remove them


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  #1  
Old 12-06-2018, 07:57:51 AM
sdowney717 sdowney717 is offline
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Default Welded new metal on top broken rusted bolts to remove them

It sure worked good. Could then grab with a vice grip and work them back and forth till out.
The broken bolts were a tiny bit raised up so made it easy to do versus if they had been deeply in the hole.
And since the rack base was rusty, little danger of weld metal sticking to it.
It sure was easier than drilling and re tapping for threads.

I also put a candle to them for oiling as I have read it helps lube up hot threads.

This is from a Polaris Sportsman 500 rack, the design is poor as the metal rack extender sits in pockets in the plastic rack. So water gets in and cant get out. I plan to drill a small side hole in each pocket to let water drain out, and grease it very well too. Both front and rear racks had the problem.
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Old 12-06-2018, 03:29:21 PM
Brad Kelley Brad Kelley is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

I've had great success removing broken studs by welding nuts on the broken end. I've had some with enough threads left to start the nut a turn or two, and plug weld the nut to the stud. The heat put into the stud from welding works great to break the rust bond, and then with a nut welded on it's easy to remove with a socket. Same method worked with a stud broken just below the surface, but I just had to be careful about the weld.
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Old 12-06-2018, 05:28:28 PM
G.M.Johnson G.M.Johnson is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

Also works good on broken off exhaust manifold head studs. Plus the heat from welding loosens up the rust and corrosion!
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Old 12-06-2018, 06:07:27 PM
sunshineman sunshineman is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

Hi
Try welding on a broken ezy-out inside a bolt broken below the surface, can only be done with low amps, stainless electrode .
Ezy out comes out first then remove stud in a manner that suits
Sunshineman
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Old 12-09-2018, 07:47:26 PM
sdowney717 sdowney717 is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

All I have is acetylene torch and an AC arc welder.
The torch has been great, paid for itself many times over, allows me to fix so many things.

I would like a TIG or MIG or something to weld SS, maybe someday.

Some larger bolts, I have burned them out of their holes, but I try to avoid that and also drilling and retapping.
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Old 12-10-2018, 02:03:42 AM
Merv C Merv C is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

I have welded nuts on broken studs many times, works every time.
When the stud remains are below the surface I use a smaller nut. it does need to be clamped down in some way. I use a stick welder. it is a little tricky to go down through the nut into the stud without welding everything together but it can be done.

Welding tends to break the rust and once cooled off the stud will shrink slightly and come out easily. It is rare for me to use an easyout, as they are prone to break. I have not been successful getting a broken stud out of Alloy this way. The alloy tends to explode. I only tried that once many many years ago.

Merv.
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Old 12-17-2018, 08:02:23 AM
sdowney717 sdowney717 is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

Preserving original threads is best.
I have never been able to use an easy out successfully, for the same reason the bolt broke off in the first place, threads glued in place with corrosion.
Bolts don't usually break off unless corroded in place.
your stuck with drilling and tapping if the bolt is too small, welding on to it gets too hard.

Some people talk about heat and a left hand drill bit, unscrews as it drills. Never seen one.
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Old 12-17-2018, 05:40:33 PM
mcostello mcostello is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

Left hand drill bits work although I don't have a set right now. Usually get the weld-a-nut to work.
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Old 12-17-2018, 09:21:41 PM
slip knot slip knot is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

I've used the welded nut before. even used a flat washer welded to the broken bolt , then a nut welded to the washer.

I recently bought a set of left handed drills and thankfully I haven't needed them yet.
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Old 12-17-2018, 09:50:07 PM
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Firewoodguy Firewoodguy is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

The fun starts when them left hand bits snap. Happened a few times, seems I had good luck with the Kobalt bits. For the $ , they are worth it. Been fighting aluminum triton engine manifold bolts past 15yrs. Had an engine last year to replace 9 broken studs. Got her done, took just under 40hrs with large washers welded to stud then the nut. Pb blaster helps. U can see it working when the heat is on. Very frustrating for anyone dealing with broken studs etc. Them triton manifolds are a pain in the #€¥!
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Old 12-17-2018, 10:15:38 PM
J.B. Castagnos J.B. Castagnos is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

Most exhaust manifold bolts are broken when the manifold continually expands and contracts, dragging the bolts back and forth with them until the heads of the bolt pop off. That's why it's usually the end bolts that break, more movement out there. These bolts aren't usually rusted in.
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Old 12-18-2018, 01:17:51 AM
cobbadog cobbadog is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

What about replacing the bolts with studs and using brass nuts like on some of our old car engines and even on our 1991 Hino truck. This way if anything fails it is the brass nut and an easy replacement fix.
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Old 12-20-2018, 06:39:17 AM
sdowney717 sdowney717 is offline
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Default Re: Welded new meatal on top broken rusted bolts to remove them

Quote:
Originally Posted by J.B. Castagnos View Post
Most exhaust manifold bolts are broken when the manifold continually expands and contracts, dragging the bolts back and forth with them until the heads of the bolt pop off. That's why it's usually the end bolts that break, more movement out there. These bolts aren't usually rusted in.
Use Stainless steel bolts. They can bend more and not break, they won't rust. I have replaced a lot of steel exhaust system bolts with SS on my boat engines and wood boat going from brass to SS above the waterline. SS is much more durable.
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