glenyoshida
03-23-2008, 05:49 PM
Hopefully you don't ever end up with a broken head on a bolt but if you do there are a few ways to remove the broken shaft. Here's a helpful link with more info Broken bolt/stripped nut link (http://www.crankshaftcoalition.com/wiki/Removing_rusted_and_broken_fasteners)
In my case the bolt broke below the face of the host metal and that made it a little more interesting. You can see how it is rusted and recessed about 1/8th". To start the little chore I whacked it a bunch of times with a hammer and punch hoping to loosen up the dirt and rust in the threads. Oh and BTW it was some yahoo before I bought the 4Runner that broke off the bolt.
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2767.jpg
I chose to weld on to the bolt. So here I'm cleaning the rust and dirt off to get a good weld.
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2768.jpg
It definitely takes a little finesse welding something like this you want as much area on the broken bolt to weld to but if you let the puddle stray you may end up welding the broken bolt in place. I recommend TIG or gas for something like this. Here's the piece of scrap welded on.
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2769.jpg
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2770.jpg
After it cooled I spayed it with PB Blaster and let it sit for a few minutes. I've run into bolts that were thread locked with locktight and one thing I've learned that really helps is to work the bolt in both directions. Tighten it as well as loosen it. Work it in clockwise and counterclockwise directions until you start to sense the movement and that may take quite a few cycles and some elbow grease. As you are working it, change direction when you feel the bolt resisting the rotation. I've been dreading and putting off trying to remove this thing for a long time but got very lucky with this and it actually came out. I really thought that I would have to drill it out and rethread it but here it is removed. I cracked myself up because I'm Atheist and I still muttered "It's a small miracle" when it worked free. Oh and it's worth noting that you want a high tensile strength metal for your weld. Every little bit helps.
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2771.jpg
In my case the bolt broke below the face of the host metal and that made it a little more interesting. You can see how it is rusted and recessed about 1/8th". To start the little chore I whacked it a bunch of times with a hammer and punch hoping to loosen up the dirt and rust in the threads. Oh and BTW it was some yahoo before I bought the 4Runner that broke off the bolt.
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2767.jpg
I chose to weld on to the bolt. So here I'm cleaning the rust and dirt off to get a good weld.
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2768.jpg
It definitely takes a little finesse welding something like this you want as much area on the broken bolt to weld to but if you let the puddle stray you may end up welding the broken bolt in place. I recommend TIG or gas for something like this. Here's the piece of scrap welded on.
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2769.jpg
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2770.jpg
After it cooled I spayed it with PB Blaster and let it sit for a few minutes. I've run into bolts that were thread locked with locktight and one thing I've learned that really helps is to work the bolt in both directions. Tighten it as well as loosen it. Work it in clockwise and counterclockwise directions until you start to sense the movement and that may take quite a few cycles and some elbow grease. As you are working it, change direction when you feel the bolt resisting the rotation. I've been dreading and putting off trying to remove this thing for a long time but got very lucky with this and it actually came out. I really thought that I would have to drill it out and rethread it but here it is removed. I cracked myself up because I'm Atheist and I still muttered "It's a small miracle" when it worked free. Oh and it's worth noting that you want a high tensile strength metal for your weld. Every little bit helps.
http://i126.photobucket.com/albums/p100/glenyoshida/Misc/Broken%20Bolt%20Removal/IMG_2771.jpg