Removing a rounded bolt from a tight space can be a frustrating and time-consuming task. However, with the right tools and techniques, it is possible to do it without damaging the bolt or the surrounding area. Here are a few effective methods to help you get the job done quickly and efficiently.
One common method for removing rounded bolts is to use a bolt extractor. This tool is designed to grip the bolt and turn it out. To use a bolt extractor, first drill a hole into the center of the bolt. Then, insert the bolt extractor into the hole and turn it counterclockwise. If the bolt is not too badly rounded, the extractor should be able to grip it and remove it. Another option for removing rounded bolts is to use a pair of locking pliers. Locking pliers are designed to grip objects tightly, even if they are rounded. To use locking pliers, simply clamp the pliers onto the bolt and turn it counterclockwise. The pliers should be able to grip the bolt tightly enough to remove it. However, if the bolt is badly rounded, the pliers may not be able to grip it tightly enough to remove it.
If the bolt is located in a tight space, you may need to use a special tool called a crowsfoot wrench. A crowsfoot wrench is a type of wrench that has a U-shaped head. This allows it to fit into tight spaces where a regular wrench cannot reach. To use a crowsfoot wrench, simply attach it to the bolt and turn it counterclockwise. The crowsfoot wrench should be able to grip the bolt tightly enough to remove it, even if it is badly rounded.
Using a Bolt Extractor
Bolt extractors are specialized tools designed to remove damaged or rounded bolts. They come in various sizes and shapes to accommodate different bolt diameters. Here’s how to use a bolt extractor to remove a rounded bolt from a tight space:
Step 1: Select the Right Size Extractor
Choose an extractor slightly smaller than the inner diameter of the bolt head. A snug fit ensures it engages with the remaining threads efficiently.
Step 2: Drill a Pilot Hole
Using a drill bit sized to the specified diameter for the extractor, carefully drill a pilot hole into the center of the bolt. Drill deep enough to penetrate the bolt’s core without damaging threads.
Step 3: Insert the Extractor
Insert the extractor into the pilot hole and ensure it grips the damaged threads securely. Use a wrench or socket to turn the extractor counterclockwise to loosen the bolt. Apply gradual force to avoid breaking the extractor or damaging the threads.
Table: Tips for Using a Bolt Extractor
| Tip | Description |
|---|---|
| Use a sharp drill bit | A dull bit can slip and damage the bolt or extractor. |
| Lubricate the extractor | A lubricant like WD-40 helps the extractor penetrate the threads smoothly. |
| Tap the extractor before inserting | Gently tapping the extractor with a hammer helps break rust or scale that could hinder its grip. |
| Don’t overtighten | Excessive force can snap the extractor or damage the threads. |
Grinding Down the Bolt Head
Use a Dremel Tool
If you have a Dremel tool with a cutting wheel, you can carefully grind down the bolt head. This method is best for bolts that are made of softer metals such as aluminum or brass. First, secure the bolt in place using a vise or clamps. Then, wear safety goggles and gloves, and hold the Dremel tool perpendicular to the bolt head. Slowly grind down the head, being careful not to cut into the threads. Once the head is thin enough, you should be able to use a wrench to loosen the bolt.
Use a Grinding Stone
Another option is to use a grinding stone mounted on a bench grinder. This method is more powerful than using a Dremel tool, so it can be used on harder bolts. However, it’s important to use caution and avoid overheating the bolt, as this can damage the threads. Secure the bolt in a vise or clamps, and then hold it against the grinding stone. Slowly grind down the head, using light pressure and moving the bolt back and forth to prevent overheating. Once the head is thin enough, you should be able to use a wrench to loosen the bolt.
Use a Hacksaw
If you don’t have a Dremel tool or a bench grinder, you can also use a hacksaw to cut a slot into the bolt head. This method is less precise than using a grinding tool, but it can be effective in a pinch. Secure the bolt in place, and then use a hacksaw to carefully cut a slot into the head. Be careful not to cut into the threads. Once the slot is wide enough, you should be able to use a screwdriver to loosen the bolt.
| Method | Pros | Cons |
|---|---|---|
| Dremel Tool | Precise, fast | Requires a Dremel tool |
| Grinding Stone | Powerful, can be used on harder bolts | Requires a bench grinder, can overheat bolt |
| Hacksaw | Effective in a pinch | Less precise, can damage threads |
Drilling Out the Bolt
Drilling the Pilot Hole
Before drilling the bolt, determine the appropriate drill bit size. The bit should be slightly smaller than the bolt’s core diameter. Use a center punch to mark the center of the bolt head for precise drilling. Place the drill bit perpendicular to the bolt head and start drilling at a slow speed, gradually increasing the pressure as you go. Drill down to a depth of about 1/4 inch, or until you reach the start of the bolt’s threads.
Enlarging the Pilot Hole
Using a drill bit slightly larger than the pilot hole, gradually enlarge the hole by drilling down to a depth of about 1/2 inch. This will create a larger cavity in the bolt’s head, weakening it and making it easier to extract.
Thread Repair
Once you’ve drilled out the bolt’s head, remove any remaining threads using a thread extractor tool. Insert the extractor into the drilled cavity and turn it counterclockwise to remove the broken threads. If the extractor doesn’t work, you may need to use a drill bit slightly larger than the thread size to enlarge the hole and weaken the threads.
Heating the Bolt
In some cases, heating the bolt can help loosen it and make it easier to remove. Use a propane torch or heat gun to heat the bolt for a few seconds. Be careful not to overheat the bolt, as this can damage surrounding components. Once the bolt is heated, try removing it using a wrench or impact driver.
Using a Bolt Extractor
Bolt extractors are specialized tools designed to remove damaged or broken bolts. They have a tapered, reverse-threaded design that grips the bolt tightly as it’s turned counterclockwise. Insert the extractor into the drilled cavity and turn it with a wrench or impact driver. As the extractor bites into the bolt, it will loosen and eventually remove it.
Using Vice Grips or Pliers
If the bolt head is still intact, you can try using vice grips or pliers to remove it. Grip the bolt head firmly with the tool and gently twist it back and forth until it loosens. This method may not work on bolts that are seized or rusted.
Drilling Out the Remaining Bolt
If all else fails, you can drill out the remaining bolt. Use a drill bit slightly larger than the original bolt’s diameter to drill down the center of the bolt. Drill carefully to avoid damaging the surrounding material. Once you’ve drilled through the bolt, use a punch or nail to drive out the remaining pieces of the bolt.
Tapping a New Bolt
This method is suitable when the rounded-off bolt is protruding from the surface. It involves tapping a new bolt or screw into the existing rounded-off bolt to create a new grip for removal. Here’s a detailed guide:
Materials Required:
| Item | Description |
|---|---|
| New bolt or screw | Slightly larger than the original rounded-off bolt |
| Hammer | For tapping the new bolt |
| Center punch | For creating a starting point for the new bolt |
Steps:
- Create a center hole: Use a center punch to create a small indentation at the center of the rounded-off bolt. This will provide a starting point for the new bolt.
- Tap in the new bolt: Align the new bolt with the center hole and tap it gently into the rounded-off bolt using a hammer.
- Apply downward pressure: While tapping, apply downward pressure on the new bolt to ensure it bites into the rounded-off bolt.
- Remove the rounded-off bolt: Once the new bolt is securely tapped in, use a wrench or socket to grip and remove the rounded-off bolt.
- Extract the new bolt: Remove the new bolt using the appropriate socket or wrench.
Additional Removal Techniques
If the methods described in the previous sections have failed to remove the rounded bolt, you can try the following additional techniques:
10. Nut Extractor Socket
A nut extractor socket is a specialized tool designed to remove damaged or rounded bolts. It features a tapered, reverse-threaded inner surface that grips the bolt and extracts it as it is turned. To use a nut extractor socket, follow these steps:
- Select a nut extractor socket that is slightly smaller than the bolt’s diameter.
- Place the nut extractor socket over the bolt and tap it lightly with a hammer to seat it.
- Turn the nut extractor socket counterclockwise using a wrench or socket wrench to remove the bolt.
| Nut Extractor Socket Sizes |
|---|
| Metric Sizes (mm): 6, 8, 10, 12, 14, 16, 18, 20, 22, 24 |
| Standard Sizes (inches): 1/4, 5/16, 3/8, 7/16, 1/2, 9/16, 5/8, 3/4, 13/16, 7/8 |
Note: Nut extractor sockets are available in various sizes to accommodate different bolt diameters. It is important to choose the correct size socket for the bolt being removed.
How To Remove Rounded Bolt From Tight Space
If you’re trying to remove a rounded bolt from a tight space, you know it can be a frustrating experience. The bolt won’t budge, and you’re starting to get worried that you’re going to damage the bolt or the surrounding area. But don’t worry, there are a few things you can try to remove the bolt without causing any damage.
First, try using a pair of locking pliers. These pliers have a special jaw that grips the bolt tightly, even if it’s rounded. Once you have a good grip on the bolt, try turning it counterclockwise to loosen it. If the bolt is still stuck, you can try using a penetrating oil. These oils are designed to seep into the threads of the bolt and break down any rust or corrosion that may be holding it in place. After you’ve applied the penetrating oil, let it sit for a few minutes before trying to remove the bolt again.
If the locking pliers and penetrating oil don’t work, you may need to use a bolt extractor. These tools are designed to grip the rounded head of a bolt and remove it. To use a bolt extractor, first drill a small hole in the center of the bolt head. Then, insert the bolt extractor into the hole and turn it counterclockwise to remove the bolt.
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 a pair of locking pliers, a penetrating oil, or a bolt extractor.
What is the best way to remove a rounded bolt from a tight space?
The best way to remove a rounded bolt from a tight space is to use a bolt extractor. These tools are designed to grip the rounded head of a bolt and remove it.
Can I use a drill to remove a rounded bolt?
Yes, you can use a drill to remove a rounded bolt. First, drill a small hole in the center of the bolt head. Then, insert a bolt extractor into the hole and turn it counterclockwise to remove the bolt.
