Broken Bolt Removal- Mixed methods
 

I have a broken bolt in a Honda exhaust header.

It is broken off about 1/8" above the flange.
https://www.miataturbo.net/attachmen...ine=1357322379

Just enough to get a bite on it with some vise grips.
https://www.miataturbo.net/attachmen...ine=1357322379

First thing I am going to do is heat it up with a torch.
https://www.miataturbo.net/attachmen...ine=1357322379

Make the area around the broken bolt glow.
https://www.miataturbo.net/attachmen...ine=1357322379

At this point , work quickly, lock the vice grips in place, and wiggle, DO NOT try to superman the broken bolt out on the first try.

Soak in WD-40, wax, engine oil.
It will smoke and stink, and watch for flare ups.
https://www.miataturbo.net/attachmen...ine=1357322379

I was able to get about a 1/4 turn befor it locked up again and the vise grips kept slipping off.

Time to try something else.....

Get a nut that just fits around the broken bolt.
https://www.miataturbo.net/attachmen...ine=1357322379

I used my old stick welder and welded the nut to the broken bolt.
https://www.miataturbo.net/attachmen...ine=1357322379

Get a wrench on there, and keep working the bolt back and forth.
https://www.miataturbo.net/attachmen...ine=1357322379

I was able to apply more force applied to the broken bolt and get it out.
https://www.miataturbo.net/attachmen...ine=1357322379

Now with the broken bolt out, I can see why it broke.
A couple threads had gaulled, and sripped some.
https://www.miataturbo.net/attachmen...ine=1357322379

I will let the header cool, then install a Heli-coil.

I was hoping you have something sneakier than the blue tipped wrench and the ol' weld a nut/bolt on trick.

Leafy... sorry! I only have about 2 more methods I use. The Whack it with a BFH, and drill and tap.

Haha, ok.

Which is the best method for bolt removal? Please share it in details. Thanks in advance.
____________________
removing broken bolts

i have great luck with just drilling a hole in the bolt, about 1/4"-1/2" deep . spray with some penetrable lube, then hammer an allen wrench into it. sounds rough but, it works. allen sockets make it easier. remember, big enough wrench for the job but, smaller hole is better. leave some wall thickness....have your fun here...

just say no to Helicoil if you have to use one. Meet my friend, His name is Kingcert.

All the info you need:

https://www.miataturbo.net/engine-pe...methods-70251/

Great information thank you, I just have one thing to say and please correct me if I am wrong. But when you heat an area of metal this hot, and than quickly cool it back down. It makes the metal stronger, but it is more brittle. I feel like people should be cautious on what parts they heat up on the car. replacing the part because of a broken bolt can put a damper on a project, But better safe than sorry...

Spencer

Dang, i was hoping for something cool.

Like a bolt broken off like a quarter of an inch down inside.
I wanted to see you build up a pad on top of it with 309 stainless. Built up far enough to get a vice grip on it and and twist it out (or whatever method from there).

That was one of my the tests for my final in my tool and die class just before i graduated. I think i took pictures of it, someday i'll dig them up.

Why does everyone make reference to stainless?? It is NOT a structural metal for the most part. It is high carbon steel at best, with corrosion inhibitors. Most of the stainless blends do not bond well with regular steel. It also has a huge thermal expansion coefficient.

You do not need to make the part " glow". A few hundred degrees is all that is needed . And be quick about it. You want the outter part to grow slightly, while keeping the bolt/ stud as cool as possible.

Um what? Most if not all stainless bolts you'll buy from the hardware store are going to be 18/8 stainless, aka 304 stainless. Which has a maximum allowable carbon content of 0.08%. Where as high carbon steel is in the 2% neighborhood.

umm, how many stainless bolts does your car have, or are we talking just generally? it is not often used on autos because of the plethora of other problems that can arise from mixing stainless with other metals. like i said, high carbon at best, often low.

watch this turn from "bolt removal" to a metallurgy debate..

Because you're a knucklehead and turned it into a metallurgy debate i now must respond, creating a further downward spiral.

READ: 309

When it bonds with mild steel (what it's also good for) it has high tensel and rotational stregth. Good for turning a bolt out. If you were to use mild steel filler on the bolt to turn it out it would just bend twist and break off.

Credits - I went to school for this.

- I've never had to do this in a real world seniro. It's uncommon, and is easier to drill and tap. Though much larger diameter bolts (1"+) this is common and effective.

And you had to start with name calling. Real cool guy.
Credit- real world experience. HA!

So that's it? That's your counter argument.

Well done sir, bravo.


** Maybe try and learn something for once in your life. ;)

Im at work gimme a bit.

Your book smarts are outstanding! Teach me more please!

I will challenge you to a fab off anytime. I have pull testing equipment if you really want to learn something, smarty pants.