Struggling to Remove a Rounded Bolt in a Deep Hole? Here's How

Removing a rounded bolt in a deep hole can be a challenging task, but with the right techniques and tools, it can be accomplished. Here are several effective methods to help you extract that stubborn bolt.

Bolt Extractor Method

Using a Bolt Extractor is one of the most straightforward methods. You'll need the appropriate bolt extractor set and a ratchet or wrench. Follow these steps:

Select the right bolt extractor size that fits over the rounded head of the bolt. Tap the extractor onto the bolt with a hammer to ensure a tight fit. Use the ratchet or wrench to turn the extractor counterclockwise. Apply steady pressure until the bolt begins to loosen.

Dremel Tool Method

The Dremel Tool is another efficient option. Equip your Dremel with a cutting disc, and follow these steps:

Carve a slot into the top of the bolt head. Use a flathead screwdriver to turn the bolt counterclockwise. Never forget to wear safety goggles to protect your eyes from metal shavings.

Welding a Nut Method

This method involves welding a nut on top of the bolt. It requires specialized welding skills and equipment. Follow these steps:

Weld a nut onto the top of the rounded bolt. Allow the weld to cool. Use a wrench to turn the nut counterclockwise.

Note: Always ensure you have the appropriate welding gear and knowledge before attempting this method.

Pry It Out Method

Using a screwdriver or pry bar is a brute force approach. Here's how to do it:

Insert a flathead screwdriver or pry bar into the gap around the bolt. Apply careful leverage to pry the bolt upwards. Try to turn the bolt while prying. However, be cautious as this method may damage surrounding materials.

Use Pliers Method

Locking pliers, such as Vise-Grips, offer a safer grip method. Here’s how to use them:

Clamp the locking pliers onto the rounded head of the bolt. Turn the pliers counterclockwise to try to loosen the bolt. This technique works best if the space around the bolt allows for a proper grip.

Apply Penetrating Oil Method

Applying penetrating oil can help soften the grip. Use a product like WD-40 and follow these steps:

Apply penetrating oil around the bolt and let it sit for a while. Try removing the bolt using one of the previously mentioned methods.

Drill It Out Method

In situations where all other methods fail, drilling the bolt out may be necessary. Ensure you have the right tools:

Use a drill with drill bits and an optional left-hand drill bit. Start with a smaller bit and incrementally increase the size until the bolt head comes off. Once the head is removed, you may be able to remove the remaining bolt shaft with pliers.

General Tips:

Always wear safety gear when working with tools. Be patient and methodical to avoid damaging the surrounding area. Consider the material and type of bolt to choose the most suitable method. If you struggle to remove the bolt, it might be best to consult a professional.

By following these detailed steps and using the right tools, you can successfully remove a rounded bolt from a deep hole. Whether you use a bolt extractor, a Dremel tool, welding a nut, prying it out with a screwdriver, using pliers, applying penetrating oil, or drilling it out, the key is persistence and the proper method.