How to Remove a Rounded Bolt | A Step-by-Step Guide

Removing a rounded bolt can be a frustrating task. Whether you are working on a DIY project or performing maintenance on a vehicle, encountering a rounded bolt can bring your progress to a halt. However, with the right tools and techniques, you can successfully remove a rounded bolt and continue with your project. In this step-by-step guide, I will walk you through the process of removing a rounded bolt.

Tools needed for removing rounded bolts

Before you begin, it’s important to gather the necessary tools. These tools will make the process easier and increase your chances of success. Here are the tools you will need:

1. Adjustable wrench or socket set: This will allow you to grip the bolt securely and apply the necessary force to remove it.
2. Penetrating oil: A good quality penetrating oil will help loosen the bolt and make it easier to remove.
3. Bolt extractor tool: This specialized tool is designed to grip onto the bolt and turn it counterclockwise, allowing for its removal.
4. Heat source: A propane torch or heat gun can be used to heat the bolt, which will expand the metal and make it easier to remove.
5. Chisel or grinder: If all else fails, you may need to resort to more aggressive methods such as chiseling or grinding the bolt to remove it.
6. Left-handed drill bit: This unique drill bit is designed to rotate counterclockwise, potentially allowing it to bite into the rounded bolt and remove it.

By having these tools on hand, you will be prepared to tackle any rounded bolt that comes your way.

How to Remove a Rounded Bolt

Step 1: Assess the situation

Before attempting to remove a rounded bolt, it’s important to assess the situation. Take a moment to examine the bolt and determine the extent of the damage. Is the bolt completely rounded, or are there still some flat edges that can be gripped? This will help you determine the best course of action for removal.

Step 2: Apply penetrating oil

Once you have assessed the situation, it’s time to apply penetrating oil to the rounded bolt. Penetrating oil works by seeping into the bolt threads and loosening any rust or debris that may be causing it to stick. Spray the penetrating oil directly onto the bolt and let it sit for a few minutes to work its magic.

Step 3: Use a bolt extractor tool

If the bolt is still somewhat grippable, use a bolt extractor tool. These tools come in a variety of sizes and are designed to grip onto the bolt and turn it counterclockwise. Insert the appropriate size extractor into the bolt and use an adjustable wrench or socket set to turn it counterclockwise. Apply steady pressure and the extractor should grip onto the bolt, allowing for its removal.

Step 4: Heat the bolt

If the bolt is still stubborn, you can try heating it to expand the metal. Applying heat to the bolt for a few minutes using a propane torch or heat gun. Be careful not to heat it too long, as excessive heat can damage surrounding components. Once heated, quickly try to remove the bolt using an adjustable wrench or socket set.

Step 5: Use a chisel or grinder

If all else fails, you may need to resort to more aggressive methods. A chisel or grinder can cut a groove into the rounded bolt, allowing for a better grip. Carefully chisel or grind away at the bolt until you have created a groove that can be gripped with an adjustable wrench or socket set. Apply steady pressure and turn counterclockwise to remove the bolt.

Step 6: Try a left-handed drill bit

Another option to consider is using a left-handed drill bit. These drill bits are designed to rotate counterclockwise, potentially allowing them to bite into the rounded bolt and remove it. Start by drilling a small pilot hole in the center of the bolt, then gradually increase the size of the hole using larger left-handed drill bits. With any luck, the drill bit will catch onto the bolt and turn it counterclockwise, allowing for its removal.

Step 7: Seek professional help if necessary

If you have tried all the steps outlined above and cannot remove the rounded bolt, it may be time to seek professional help. A professional mechanic or handyman will have the experience and specialized tools to tackle even the most stubborn rounded bolts. Don’t hesitate to reach out for assistance if needed.

My Opinion

Removing a rounded bolt can be challenging, but with the right tools and techniques, it is possible to overcome this obstacle. Remember to assess the situation, apply penetrating oil, and use the appropriate tools for removal.

Taking preventive measures, such as regularly lubricating bolts and using the correct tools and torque when fastening, can help avoid rounded bolts in the future. By following this step-by-step guide, you will be well-equipped to tackle rounded bolts and easily continue your projects.