Get That Stuck Bolt Out ... And Do It Fast!

A stuck bolt costs time and money.

It is among the worst nuisances anyone in a shop can deal with. There are several options to make a stuck nut or bolt become unstuck in a timely manner, and we are here to help you work through it.

No matter which option you take in trying to remove a stuck fastener, you should always start with a wire brush.

Brush off any flaky rust that’s in the way. That will help in every option. If you use chemicals, it won’t absorb into the rest instead of getting at the problem. If you use hand tools, it will allow a proper fit. If you have to turn to heat, it won’t absorb the energy you need to get to the nut or bolt to make the part expand.

Below are your options when it comes to removing stuck fasteners. We suggest going in order, but it’s your shop!

Option 1: Chemicals and Hand Tools

Find a great penetrating oil and hit the part with a liberal amount. This will likely run off a bit, so make sure you cover any painted surfaces that might be below. Also, be sure to read the label. Most penetrating oils will need to sit for a few minutes to work.

If the bolt is horizonal, consider using an extended contact penetrating oil, if you have one available, so it doesn’t immediately drip off.

Once that’s soaked for a few minutes, grab your hammer. You are probably frustrated, so take a deep breath first. Give a few light taps with a hammer to break the mating surfaces loose. Hitting it hard will only serve to damage some parts – we are talking 25% to 50% force.

Now it’s time to grab the wrench or socket wrench. We recommend a six-sided wrench for a better grip. We have found 12-sided sockets or wrenches can round off bolts and don’t achieve nearly as good of a grip, and you need as much grip as you can get.

If you are working on a bolt that’s been rounded, try using a bolt extractor. More on that below.

If you are giving it a turn and it just won’t budge, consider a tool extender for added torque. The longer handle gives you more force and may do the trick. But be careful. You don’t want to break the bolt.

Option 2: Heat

Heating the parts expands the metal and breaks the bonds holding the fastener system together.

There are multiple options here. We recommend a torch or an induction heat tool. The induction heat tool is a much safer option when used properly.

When using an option like the Bolt Buster, slow and steady wins. In an effort to preserve both the tool and the work piece, heat the fastener slowly and evenly. You only need to get it hot enough for the metal to expand and hopefully separate the parts. With the bolt still hot, use a wrench to remove it.

Please be sure to use gloves and be careful as these parts and the work piece can stay hot for some time after. Have a metal can filled with water to throw the hot nut and bolt in to cool down.

Option 3: Extractors and the Worst-Case Scenario

The bolt was just too stubborn and broke. It happens. But you still have a good chance at getting it removed and saving the piece.

It’s time to move on to extractors. Choose a left-handed drill bit and grab a drill that has a reverse. Choose a bit roughly 2/3 the size of the bolt you are drilling into. Find the center of the bolt and cut a hole into it.

There are a few good things happening here. Because you are going in reverse, you won’t continue to tighten the bolt. Also, this could pull out the fastener because of the force of the drill.

If it doesn’t, that’s OK because you were drilling a hole for an extractor anyway.

Place the extractor into the hole, then give it a few taps with a hammer to make sure it grabs. With the extractor engaged, use whatever tool you’d like to back the stuck bolt out and get on with the next portion of your job.

As mentioned above, for rounded bolts, we recommend using the Turbo Torq™ Extractor. The extractor’s left-hand twist will dig into the bolt to assist in removal. The Tool and Wrench Extender can also be of service.

We also have a great extractor kit we think you’ll like, our Super Pimalloy+ Extractors and Stubby Left-Hand Drill Bit Set, which contains sizes from 3/32” to 5/16” and is ready for any job. Larger sizes are available, too.

And of course, for penetrating oil we recommend our best seller, Torq “CB”.

We hope your bolt is no longer stuck and you have been able to move on with your project. If you need any more help or want more information on any one of our products, feel free to ask your rep. If you don’t have a rep, we can help you