Manual Bolt Removal Guide

We often get calls about broken bolts in vehicles. Our service generally does not work well for those situations as we need to position the EDM machine to 90 deg of the bolt / screw.

But we are still here to help.

Here's our guide, and recommendations for how to remove a bolt. These are just suggestions and be careful.

Summarized Procedure - How to Remove Broken Bolts:

1. Assess: Identify the bolt, its condition (rust, tightness), and your access. Take time to clean well so you can see the following steps.

2. Prepare: Gather necessary tools (wrenches, sockets, hammer, penetrating oil, safety glasses, EZ-Out set, drill bits, center punch).

3. EZ-Out Method (for broken bolts):

   • Center punch the broken bolt. As close to center as possible (take your time)

   • Depending on how big you're going - Drill a pilot - pilot hole.

   • Drill a pilot hole (slightly smaller than the EZ-Out or extractor). BUY

   • Insert and seat the EZ-Out.

   • Spray penetrating oil around the treads - wait 10-15 mins  - BUY

   • Carefully turn the EZ-Out counterclockwise.

4. Post-Removal: Inspect the bolt, area, and clean up. Chase the threads if needed.

Full Procedure - How to Remove Bolts: Tools and Techniques for Effective Bolt Removal

Introduction

Removing bolts can be a daunting task, especially when they are stuck due to rust, over-tightening, or corrosion. Whether you're a DIY enthusiast or a professional mechanic, having the right tools and knowing the correct techniques are crucial for efficient and safe bolt removal. This guide covers essential tools like EZ-Outs and the use of penetrative lubricants to make your job easier.

1. Understanding Bolt Removal

Why Bolts Get Stuck

• Corrosion and Rust: Environmental factors can cause bolts to rust, making them hard to turn.

• Over-Tightening: Applying excessive force during installation can make bolts difficult to remove.

• Dirt and Debris: Accumulation of dirt can impede bolt movement.

Safety Precautions

• Protective Gear: Always wear gloves and safety glasses.

• Proper Tools: Use tools that fit correctly to avoid slipping and injury.

• Stable Workspace: Ensure your work area is stable to prevent accidents.

2. Essential Tools for Bolt Removal

Wrenches and Sockets

• Types of Wrenches: Open-end, box-end, and adjustable wrenches.

• Socket Sets: Comprehensive socket sets can handle various bolt sizes and types.

Impact Drivers and Wrenches

• Impact Drivers: Provide higher torque for stubborn bolts without damaging the tool or bolt.

• Impact Wrenches: Ideal for heavy-duty applications where significant force is required.

3. Using Penetrative Lubricants

What is a Penetrative Lubricant?

Penetrative lubricants are specially formulated oils that seep into tight spaces between threads, breaking down rust and corrosion to free stuck bolts.

Top Penetrative Lubricants

• WD-40 Specialist Penetrant: Fast-acting and effective on most rusted bolts. BUY

• PB Blaster Original: Known for its powerful penetration capabilities. BUY

• Liquid Wrench Penetrating Oil: Long-lasting formula that protects against future rust. BUY

How to Apply Penetrative Lubricants

1. Clean the Bolt: Remove any surface dirt or debris.

2. Apply Generously: Spray the lubricant directly onto the bolt and surrounding area.

3. Allow to Soak: Let it sit for at least 10-15 minutes to penetrate.

4. Attempt Removal: Use the appropriate tool to turn the bolt. Repeat if necessary.

Tips for Maximum Effectiveness

• Apply lubricant from multiple angles.

• For severely rusted bolts, allow the lubricant to soak overnight.

• Reapply as needed during the removal process.

4. EZ-Outs: Specialized Tools for Bolt Extraction

What are EZ-Outs?

EZ-Outs are specialized extractor tools designed to remove broken or stripped bolt heads. They provide a secure grip on the bolt, allowing for effective extraction without further damage.

Types of EZ-Outs

• Standard Extractors: Suitable for common bolt sizes and types.

• Heavy-Duty Extractors: Designed for larger, more stubborn bolts.

How to Use EZ-Outs

1. Select the Right Size: Choose an EZ-Out that fits the bolt’s dimensions.

2. Drill a Pilot Hole: Carefully drill a small hole into the center of the stripped bolt - use a center punch to get the center marked..

3. Insert the EZ-Out: Place the extractor into the hole.

4. Turn Counterclockwise: Use a wrench to slowly turn the extractor, which grips and removes the bolt.

Product Recommendations

• PTSTEL - 35Pcs Extractor Set: Comprehensive set with various extractor sizes. BUY

• GearWrench EZ-Out Set: Durable and comes in multiple sizes. BUY

• XEWEA EZ-Out Extractor Set: Affordable and reliable for home use. BUY

• Straight Fluted Screw Extractor: Square extractors. BUY

Additional Tips and Tricks

Heat Application (Careful)

Applying heat to a stuck bolt can expand the metal, making it easier to turn. Use a propane torch carefully to heat the bolt for a few minutes before attempting removal.

Using Impact Tools

Impact drivers and wrenches can deliver high torque in short bursts, which helps break loose stubborn bolts without stripping them.

Preventing Future Bolt Seizing

• Regular Maintenance: Clean and lubricate bolts periodically.

• Use Anti-Seize Compounds: Apply anti-seize lubricant during installation to prevent rust and corrosion.

Safety Considerations

• Wear Protective Gear: Gloves and safety glasses protect against injuries.

• Proper Tool Use: Ensure tools are in good condition and used correctly to prevent accidents.

• Stable Work Environment: Keep your workspace organized and free from hazards.

For a free quote, email us: info@tapouttexas.com or Call 832-240-6312