1. Safety First
When bolts snap, things can quickly escalate into the realm of dangerous. The force it took to snap the bolt could have also damaged surrounding parts, including potentially the tool you are trying to use. So, take precautions. Wear appropriate PPE including gloves and safety glasses. Make sure your tools are in good condition and sharp (dull tools often require more force to use, which could make the situation worse).
[Image of a man with PPE working on a vehicle with a caption: “Safety First”]
2. Clean Around the Bolt
Grab your trusty wire brush or a can of brake cleaner depending on what the bolt and surrounding area will tolerate. A clean environment will give you better visibility and reduce the chances of shavings or dirt contaminating the fix.
[Image of a mechanic cleaning around a bolt with a caption: “Clean Around the Bolt”]
3. Assess the Bolt
Figure out what you’re up against. Is most of the bolt still sticking out? Is it flush, or has it broken below the surface? Is it rusted or seized in place? Knowing what you are dealing with will determine the best approach to removing the snapped bolt.
[Image of a man inspecting a snapped bolt with a caption: “Assess the Bolt”]
4. Try to Grip It
If there is enough of the bolt exposed, you might be able to grip it with a pair of locking pliers, a pair of vice grips, or even a pair of regular pliers. Turn the bolt counterclockwise to loosen it. If the bolt is too damaged or rounded, you may need to use an alternative method.
[Image of a man using pliers to grip a snapped bolt with a caption: “Try to Grip It”]
5. Use an Easy-Out Tool
An Easy-Out tool is a tapered, fluted tool, often made from hardened steel, that is designed to bite into the broken bolt and allow you to remove it. Drill a hole into the center of the broken bolt, tap the Easy-Out into the hole, and then use a wrench to turn the Easy-Out counterclockwise to remove the bolt.
[Image of a man using an Easy-Out tool to remove a snapped bolt with a caption: “Use an Easy-Out Tool”]
6. Use an extractor
Bolt extractors are another option for removing snapped bolts. They are typically made from hardened steel, and they have a reverse-threaded tip that bites into the broken bolt. Drill a hole into the center of the broken bolt, tap the extractor into the hole, and then use a wrench to turn the extractor clockwise to remove the bolt.
[Image of a man using an extractor to remove a snapped bolt with a caption: “Use an Extractor”]
7. Weld a Nut
If the broken bolt is protruding slightly, you can weld a nut onto the end of the bolt. Once the nut is welded on, you can use a wrench to turn the nut and remove the bolt. This method is not suitable for all situations, such as when the bolt is made of a material that cannot be welded.
[Image of a man welding a nut onto a snapped bolt with a caption: “Weld a Nut”]
8. Use a Dremel Tool
A Dremel tool is a versatile rotary tool that can be used for a variety of tasks, including removing snapped bolts. Use a cutting disc to cut a slot into the head of the broken bolt. Then, use a screwdriver or an Allen key to turn the bolt counterclockwise to remove it.
[Image of a man using a Dremel tool to remove a snapped bolt with a caption: “Use a Dremel Tool”]
9. Use a Cold Chisel
A cold chisel is a hardened steel tool that is used for cutting or shaping metal. You can use a cold chisel to split the head of a snapped bolt. Once the head of the bolt is split, you can use a punch to drive out the remaining portion of the bolt.
[Image of a man using a cold chisel to remove a snapped bolt with a caption: “Use a Cold Chisel”]
10. Use a Hammer and Punch
If the bolt is flush or below the surface, you can use a hammer and punch to drive it out. Place the punch on the center of the bolt and tap it with a hammer. Gradually increase the force until the bolt is driven out.
[Image of a man using a hammer and punch to remove a snapped bolt with a caption: “Use a Hammer and Punch”]
