Impossible bolt- need tricks and suggestions
 

I use versions of these.



https://cimg5.ibsrv.net/gimg/www.mia...06b42c0f90.jpg

How about you do it the right way and replace the bolt and nut?

I don't think you're going to fit a nut splitter over the nut because it's too close to the block.

It's time to remove one end of the bolt -- the head is probably easier to get to, so I'd try that. Drill, dremel, cutoff wheel, something like that. You might need to pull the motor + tranny together and do it out of the car.

--ian

Dremel to start, air chisel to finish. Come in from the wheel well. Don't overtighten it next time :)

Right, whats the first step in replacing a bolt and nut? Removing the bolt... Thanks though guy

Alright everyone, looks like I finally have an excuse to buy a dremel! Thanks for the replies.

If you don't already own the Dremel, don't buy one. They are awful. Get a proper rotary tool that will fit that space, something like a Milwaukee M12 or similar.

I would argue this point.

I've had the same corded multi-speed dremel tool for about the past 15 years. If their quality has gone downhill in recent years, then I'll retract this comment. But I have beat the absolute hell out of that tool, and it's never let me down. I wish I could post a photo and the model number, but I left it at work this weekend, as I've been using it to modify a set of 30 year old Vinten Fulmar camera pedestals to accept a modern robotic head, and also to lock their leaky pneumatic columns in place.

Would I spec this tool for use on an assembly line where it'll be in service for two shifts every day? Hell no. It's a consumer-grade product. But for my needs, it does the job well.

For small items and small jobs, they are fine. The problem is that nothing on a car is small enough to justify its size and corresponding lack of power. I owned one and threw it away after the collet lock snapped off, dooming it to a lifelong marriage with a broken router bit.

For cutting through the nut and shaft of an M12 bolt, I would not suggest one.

Assuming that you are only doing it occasionally, I would endorse a corded Dremel product for this task. I have used it for much larger jobs. Takes a while, but the light weight and small size make it a winner for me.

Agreed. There are much better tools for working on things than a Dremel. They are for the person who lives in an apartment and only has one power tool.

I thought you were trying to JB Weld the nut in place. Thanks for the negatives.

The answer to getting it off is a cold chisel; split the nut.

A dremel will cut an M12 bolt just fine. I wouldn't recommend it as a primary metalworking fabrication tool, but they're useful tools to have for miscellaneous small jobs.

--Ian

When i crack my boat (wood) i use a dremel to router out the crack before applying filler. Dremel is good for light, delicate work, even if it's a big job. In the scenario in which i need to grind down a half inch bolt head, a dremel isn't my first thought. It just doesn't have the balls.

For that i use this:

I'd use a cutting disc to cut the head off, rather than trying to grind it all away. Dremel will do that fine.

--Ian

These little guys?

Even with these the Dremel stalls out, chews them up too quickly, or doesn't cut off material.
https://cimg6.ibsrv.net/gimg/www.mia...9db59f2203.jpg

It will do this, indeed.

I just don't know guys. I'm probably doing something completely wrong with my dremel. Don't get me wrong, i absolutely love it and i know it has it's place. But man i just don't remember it cutting through metal, specifically a bolt head that easily.

With a fiberglass cutting disc it's a mini cutoff wheel. Cuts metal just fine.

https://images-na.ssl-images-amazon....1SBKbfzujL.jpg

The teeny ones you pictured will vanish instantly, but the fiberglass ones last a lot longer.

--Ian

(Edit: As I said, I wouldn't recommend going out and buying one just for this purpose, but if you've got one available it will certainly do it)

Even better than the above is the EZ-Lock kit:

https://www.homedepot.com/p/Dremel-E...Z406/100484370




https://cimg1.ibsrv.net/gimg/www.mia...9b349da9e3.png


These are basically miniature angle-grinder blades, and come with a handy quick-change collet. This is the shaft that I have in my dremel 90% of the time. The EZ-change discs are slightly larger and thicker than the screw-type version, and seem to made of sterner stuff. I very rarely break them.

This is the first tool I think of when tasked with "I need to cut through a bolt in a tight space." I've used them on tool steel, hardened steel shafts, steel plate, etc. Sometimes you use up more than one disc on a job, but the small size allows you to get them into places which are otherwise inaccessible.

I never knew those even existed. I'll certainly give them a shot.

You might be able to plunge cut it with an oscillating multi tool with a carbide bit.

I'd loosen the rest of the bolts, wedge a pry bar in to get some pressure put on the bolt/nut, then rattle gun it off. Threads fucked, might as well fuck the rest of them.

I have a Ryobi version of the Dremel and it is good quality. Sometimes the access requires a smaller tool like the Ryobi. I prefer the air cut-off wheel for slightly larger jobs and the angle grinder with a cut-off wheel for the ones with good access. You can never have enough cutting tool variety in your arsenal.

My first few (Sch. 40) manifold were cut with these. IIRC For Sav's I ended up using the quick connect wheels Mr. Perez noted.

Successfully annihilated the nut with those fiberglass wheels. That was probably the biggest nut I've ever busted

Pos+Cat given for this tip - never knew about them and will come in handy in future.

I've used a Dremel with regular cut-off wheels to cut a nut off a sway bar that the owner manager to round off beautifully.
That took ages and several cutting wheels due to them wearing quickly and snapping if I used the wrong angle.
When I finished I looked like a WWI fighter ace, there was black crap all over my face except where the safety goggles had been.

Tip: If you start rounding off a nut/bolt, switch to another tool, the one you're using is just making things worse!

Unfortunately those nut-busters/crackers tend not to fit in the spaces where you need them and often you can't even fit it over the nut because they're so thick :(
I've got 2 in my collection though because they're worth trying first.

Drill a pilot hole in the nut, then a larger hole, then air chisel to split the nut.

I like the EZ dremel wheels. I've had a few of them separate though so be mindful!

The dremel metal cutting discs work well, but IME don't last very long (they get chewed up quick). But at least they don't just shatter at a slight touch like the brown dremel discs!