How To Unscrew A Rounded Bolt
Stripped, rounded bolts are a nightmare to deal with, especially when you’re trying to get a job done quickly and efficiently. Anyone who’s ever tried to remove a rounded bolt knows how frustrating it can be. The more you try to turn it, the more rounded it becomes, and the harder it is to get a grip on it.
But don’t despair! With the right tools and techniques, it is possible to remove even the most stubborn rounded bolts. In this article, we’ll show you a few different ways to do it. So next time you’re faced with a stripped bolt, don’t reach for the bolt cutters just yet. Try one of these methods instead. Armed with these tips, you’ll be able to tackle any rounded bolt with confidence.
First, try using a pair of pliers or a wrench to grip the bolt. If that doesn’t work, you can try using a hacksaw to cut a slot into the bolt head. Once you’ve cut a slot, you can use a screwdriver to turn the bolt. If the bolt is still too tight, you can try using a penetrating oil to loosen it up. Let the penetrating oil soak in for a few minutes, then try to turn the bolt again. With a little patience, you should be able to remove even the most stubborn rounded bolt.
Tools for Removing Rounded Bolts
Removing a rounded bolt can be a frustrating experience, but it’s certainly not impossible. With patience and the right tools, you can successfully extract the bolt without damaging it or the surrounding area.
Tools for Removing Rounded Bolts
Extractor Sockets
Extractor sockets, also known as bolt extractors or screw extractors, are designed to grip and remove damaged or rounded bolts. These sockets have left-handed threads, which means they turn in the opposite direction of the bolt. As you turn the extractor socket, the left-handed threads bite into the rounded bolt and gradually unscrew it.
Extractor sockets come in various sizes to accommodate different bolt diameters. When selecting an extractor socket, choose one that is slightly smaller than the bolt. This allows the extractor socket to engage with the maximum number of threads on the bolt and improve its grip.
To use an extractor socket, simply insert it over the rounded bolt and turn it counterclockwise using a socket wrench. If the bolt is particularly stubborn, you may need to apply some force or use a penetrating lubricant to loosen it.
Bolt Size |
Extractor Socket Size |
|---|---|
| 1/4 inch | 3/16 inch |
| 5/16 inch | 7/32 inch |
| 3/8 inch | 1/4 inch |
| 1/2 inch | 5/16 inch |
| 5/8 inch | 11/32 inch |
Methods for Unscrewing Rounded Bolts
Using a Bolt Extractor
Bolt extractors are specifically designed tools for removing damaged or rounded bolts. They come in a range of sizes to fit different bolt heads. To use a bolt extractor, first select the appropriate size and insert it into the rounded bolt head. Then, using a wrench or socket, turn the extractor counterclockwise to grip the bolt and remove it.
There are two main types of bolt extractors: spiral flute and reverse flute. Spiral flute extractors are the most common type and have a spiral groove cut into the end that digs into the bolt head as it is turned. Reverse flute extractors have a reversed spiral groove that grips the bolt head from the inside out. Both types of extractors can be effective for removing rounded bolts, but spiral flute extractors are generally more versatile and easier to use.
| Extractor Type | Advantages | Disadvantages |
|---|---|---|
| Spiral Flute | Versatile, easy to use | Can slip if not properly engaged |
| Reverse Flute | Strong grip, less likely to slip | Can damage bolt if not used carefully |
Using a Hammer and Chisel
If a bolt extractor is not available, a hammer and chisel can be used to remove a rounded bolt. To do this, first place the chisel on the edge of the bolt head and strike it with a hammer to create a notch. Then, insert the chisel into the notch and use the hammer to twist the bolt head counterclockwise. Repeat this process until the bolt is loosened and can be removed.
Using a hammer and chisel to remove a rounded bolt is a more difficult and time-consuming method than using a bolt extractor. However, it can be effective if other methods are not available. It is important to use caution when using a hammer and chisel, as they can easily damage the bolt or surrounding materials.
Extracting a Damaged Bolt
When screws or bolts have stubborn heads or become stripped, removing them can be challenging. However, with the right tools and techniques, you can effectively extract damaged bolts, even if they’re rounded off.
Using an Impact Wrench
An impact wrench delivers sudden, high-torque impacts to loosen bolts quickly. Follow these steps:
- Position the impact wrench perpendicular to the bolt’s head, ensuring a secure fit.
- Apply brief bursts of power, alternating clockwise and counterclockwise while maintaining constant pressure.
- Continue until the bolt loosens. Note that using excessive force can damage the tool or the bolt.
Drilling and Tapping the Bolt
When a bolt’s head is badly damaged, drilling and tapping may be necessary. This method involves creating a new groove within the bolt’s body to remove it:
- Select a drill bit slightly smaller than the bolt’s diameter.
- Drill a hole carefully in the center of the bolt’s head, using a high-speed setting with light pressure.
- Insert a bolt extractor (a specialized tool with reverse threads) into the drilled hole. Tap the extractor with a hammer to bite into the bolt.
- Use a wrench to turn the extractor counterclockwise to loosen the bolt.
Using an Extractor Socket
Extractor sockets are specially designed tools that grip stripped or rounded bolts. They come in various sizes to accommodate different bolt diameters:
- Identify the appropriate extractor socket size for the bolt.
- Insert the extractor socket over the bolt’s head, ensuring a secure fit.
- Turn the extractor socket counterclockwise with a wrench to engage its teeth on the bolt’s sides.
- Continue turning the socket until the bolt loosens.
| Method | Tools Required |
|---|---|
| Impact Wrench | Impact wrench, sockets |
| Drilling and Tapping | Drill, drill bits, bolt extractor |
| Extractor Socket | Extractor sockets, wrench |
Using Reverse Drilling
For more stubborn rounded bolts, you may need to use a drill to remove them. This technique is known as reverse drilling, and it involves using a drill bit that is smaller than the bolt to drill a pilot hole into the center of the bolt. Once the pilot hole is deep enough, you can use a larger drill bit to remove the remaining material around the bolt, eventually freeing it from the surface.
Detailed Steps for Reverse Drilling:
- Select a drill bit that is smaller than the diameter of the bolt.
- Set the drill to reverse mode (counterclockwise).
- Center the drill bit on the rounded bolt and apply pressure to start drilling.
- Drill a pilot hole about 1/4 inch deep into the center of the bolt.
- Switch to a larger drill bit that is just slightly larger than the diameter of the pilot hole.
- Continue drilling in reverse mode, gradually removing the material around the bolt.
- As the material thins, you may need to switch to smaller drill bits to avoid damaging the surrounding surface.
- Once the bolt head is completely removed, you can use pliers or a vise-grip to remove the remaining bolt.
| Drill Bit Size | Bolt Size |
|---|---|
| 1/8 inch | 1/4 inch to 5/16 inch |
| 3/16 inch | 5/16 inch to 3/8 inch |
| 1/4 inch | 3/8 inch to 1/2 inch |
Employing a Bolt Extractor
A bolt extractor, also known as an EZ-out or a screw extractor, is a specialized tool specifically designed to remove rounded or damaged bolts. These extractors feature a reverse-threaded design that bites into the damaged bolt as it is turned counterclockwise, allowing you to extract the bolt without further damaging it.
To use a bolt extractor, follow these steps:
- Select the Correct Size: Determine the size of the damaged bolt and choose an extractor that matches the bolt’s diameter.
- Drill a Pilot Hole: Drill a small pilot hole into the center of the rounded bolt head. The size of the pilot hole should be slightly smaller than the diameter of the extractor’s tip.
- Insert the Extractor: Insert the extractor’s tip into the pilot hole and tap it in with a hammer or mallet to ensure it is seated securely.
- Turn Counterclockwise: Use a wrench or socket to turn the extractor counterclockwise. As you do this, the extractor’s reverse threads will bite into the bolt and loosen it.
- Remove the Bolt: Continue turning the extractor counterclockwise until the bolt is completely removed. [Additional Detail] If the bolt is particularly stubborn, you may need to repeat steps 3 and 4 a few times to fully extract the bolt. Alternatively, you can try applying a penetrating oil or lubricant to the bolt to help loosen it.
- Clean the Extractor: Once the bolt is removed, clean the extractor thoroughly with a degreaser or solvent to remove any metal shavings or debris. This will ensure its longevity and prevent contamination during future use.
Applying a Pipe Wrench
A pipe wrench is another effective tool for removing rounded bolts. It provides a more secure grip than a standard wrench thanks to its adjustable jaws.
Steps for Using a Pipe Wrench
1. Choose the Correct Wrench: Select a pipe wrench that is large enough to fit around the bolt head without slipping.
2. **Position the Wrench: Place the jaws of the pipe wrench over the bolt head and adjust the handle to create a snug fit.
3. **Apply Pressure: Grip the handle of the wrench firmly and pull or push in the direction needed to loosen the bolt.
4. **Use a Cheater Bar (Optional): For stubborn bolts, consider using a cheater bar to extend the leverage of the pipe wrench. Slip the cheater bar over the handle and pull or push.
5. **Avoid Excessive Force: Be careful not to overtighten the wrench or apply excessive force, as this can further damage the bolt head.
6. **Additional Tips:**
- For extra grip, place a piece of sandpaper or a thin cloth between the jaws of the wrench and the bolt head.
- If the bolt is particularly tight, try tapping the wrench with a hammer to break it loose.
- Always wear safety glasses when using a pipe wrench, as fragments from a damaged bolt could fly off.
Utilizing a Hacksaw
Utilizing a hacksaw entails meticulously cutting through the bolt’s head. This method is particularly effective when the bolt is inaccessible from the opposite side or if it’s situated within a confined space. To execute this technique effectively, follow these steps:
- Select a hacksaw that can accommodate a blade suitable for the bolt’s material and size.
- Secure the hacksaw blade into the frame.
- Position the hacksaw perpendicular to the bolt’s head and apply consistent pressure while cutting.
- Maintain a steady and controlled motion throughout the process.
- Check the depth of the cut periodically and adjust the sawing angle as necessary to ensure a straight and even cut.
- Once the groove is sufficiently deep, rotate the hacksaw 90 degrees and begin sawing another groove perpendicular to the first one.
- Continue sawing until the grooves intersect and the bolt head is severed into two sections.
- Using a flathead screwdriver or chisel, gently pry apart the severed sections of the bolt’s head.
- Use a wrench or pliers to grip and unscrew the bolt’s body from the workpiece.
This method offers versatility, as it can be successfully employed on various sizes and types of rounded bolts, including those that are partially obstructed or damaged.
Grinding Down a Wrench
Option #8: Grinding Down a Wrench
This approach requires specialized tools and a bit more finesse, but it can be a highly effective technique for removing rounded bolts. Follow these steps:
- Choose the Correct Wrench: Select a wrench that is slightly larger than the rounded bolt. The goal is to create a new surface that can grip the bolt.
Creating a New Grip
- Grind the Wrench: Use an angle grinder to grind down one of the wrench’s jaws. The modified jaw should be slightly narrower than the bolt’s diameter.
- Test the Fit: Test the modified wrench on the bolt to ensure it fits snugly. If necessary, grind the jaw further to adjust the fit.
- Apply Friction: Wrap a piece of abrasive material, such as sandpaper or emery cloth, around the modified wrench jaw. This will increase friction and prevent slippage.
- Apply Force: Place the modified wrench on the bolt and apply steady force. Gradually turn the wrench counterclockwise to unscrew the bolt.
| Advantages | Disadvantages |
|---|---|
| Can remove severely rounded bolts | Requires specialized tools and skills |
| Effective on various bolt sizes | Time-consuming if multiple bolts need removal |
Heating the Bolt
Perhaps the most effective method of dealing with a rounded bolt is to apply heat. Heat can expand the metal surrounding the bolt, making it easier to grip and loosen.
To heat the bolt, you can use a propane torch or a soldering iron. If you’re using a torch, be sure to hold the flame away from the bolt and apply heat for only a few seconds at a time. If you’re using a soldering iron, apply heat for a longer period of time, but be careful not to overheat the bolt and damage it.
Once the bolt is heated, try to remove it using a wrench or a pair of pliers. If it still won’t budge, you can try heating it again and applying more force. However, if the bolt is too rusted or corroded, you may need to use a more drastic method, such as drilling out the bolt or cutting it off with a hacksaw.
Here are some additional tips for heating a rounded bolt:
- Use a heat-resistant wrench or pliers to protect your hands.
- Don’t overheat the bolt, as this can damage it.
- If the bolt is still difficult to remove, you can try applying penetrating oil to it.
- If you’re unable to remove the bolt, you may need to drill it out or cut it off.
| Pros | Cons |
|---|---|
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Preventative Measures for Bolt Stripping
1. Use the Right Tools
Utilize a wrench or socket that fits the bolt snugly to prevent slippage. Avoid using adjustable wrenches, as their imprecise grip can lead to stripping.
2. Apply Pressure Evenly
Apply pressure perpendicular to the bolt head, avoiding any sideways forces. This ensures equal distribution of torque, minimizing the risk of damage.
3. Clean the Bolt
Remove any dirt or debris from the bolt head and threads using a wire brush or cleaning solution. A clean surface allows for better tool engagement and reduces friction.
4. Lubricate the Bolt
Apply a small amount of penetrating oil or lubricant to the bolt threads. This reduces friction and helps the tool penetrate stubborn threads.
5. Use an Impact Driver
An impact driver delivers rapid bursts of torque that can loosen stubborn bolts without excessive force. However, it’s crucial to use a socket specifically designed for impact drivers to prevent damage.
6. Heat the Bolt
Heating the bolt with a heat gun or torch can expand the metal, loosening its grip on the threads. However, avoid excessive heat, as it can weaken the bolt.
7. Tap the Bolt
Use a hammer or mallet to lightly tap the bolt head in the direction of travel. This vibration can help break the bond between the bolt and threads.
8. Use a Drill Bit
If all else fails, consider using a drill bit slightly smaller than the bolt diameter. Drill into the bolt head, and the weakened material may allow you to remove it with a screwdriver.
9. Extract the Bolt
If the bolt is severely stripped, an extraction tool may be necessary. These tools grip the remaining bolt material and allow for its removal.
10. Preventative Maintenance
Regularly inspect nuts and bolts, ensuring they are tight and not corroded. Use appropriate torque when tightening, and protect bolts from moisture and debris with anti-seize compounds or sealant.
| Maintenance Practice | Benefits |
|---|---|
| Regular Inspections | Identify loose or corroded bolts |
| Proper Torque | Prevents overtightening and stripping |
| Anti-Seize or Sealant | Reduces corrosion and makes future removal easier |
| Clean and Lubricate | Improves tool engagement and prevents friction |
How To Unscrew A Rounded Bolt
If you’ve ever tried to unscrew a rounded bolt, you know how frustrating it can be. The more you try to turn it, the more rounded it becomes, and the more difficult it is to remove. But there are a few tricks you can try to get that bolt out without damaging it or the surrounding area.
First, try using a pair of vice grips. Grip the bolt as close to the head as possible, and then try to turn it. The vice grips will provide you with more grip than your fingers, and they may be able to break the bolt loose.
If that doesn’t work, you can try using a bolt extractor. A bolt extractor is a tool that is specifically designed to remove rounded bolts. It has a reverse-threaded tip that bites into the bolt, and then you can use a wrench to turn it out.
If you don’t have a bolt extractor, you can try using a hammer and chisel. Place the chisel on the edge of the bolt, and then hit it with the hammer. This will create a notch in the bolt, which you can then use a screwdriver to turn. This is a more difficult method, but it can be effective if you’re careful.
Once you’ve removed the rounded bolt, be sure to replace it with a new one. This will help to prevent the problem from happening again.
People Also Ask
How do you remove a rounded bolt head?
There are a few ways to remove a rounded bolt head. You can try using vice grips, a bolt extractor, or a hammer and chisel. If none of those methods work, you may need to drill out the bolt.
How do you unscrew a stripped bolt?
There are a few ways to unscrew a stripped bolt. You can try using a bolt extractor, a rubber band, or a pair of pliers. If none of those methods work, you may need to drill out the bolt.
How do you get a bolt out that is rusted on?
There are a few ways to get a bolt out that is rusted on. You can try using a penetrating oil, a heat gun, or a hammer and chisel. If none of those methods work, you may need to drill out the bolt.
