welding bolts to remove them.

Kendrick · Oct 7, 2011

I have a stick welder and need to remove 3 recessed special shaped screws for my car door lock and the brake actuator on my truck. the truck bolt is straight forward and will probably not be a problem. the car is another story.

They have degenerated fairly badly. I stuck a screwdriver in and turned quite easily looked down and the screw wasnt turning it had no strength in the head.

KennyG · Oct 7, 2011

You might be able to tack something onto the head to grab and turn it, but there are a lot of things that could go wrong. I've had lots of luck in these situation with a handheld impact driver.

ch47dpilot · Oct 7, 2011

I use a mig so not sure if this will work with a stick welder. Use a nut that the inside is smaller than the outside of the head. Plug weld inside the nut to the bolt head. then just use a socket on the nut to loosen bolt. The heat from welding usually helps break the old rust and stuff free. this works great it you break a bolt off inside something like an engine block. But for that use the same size nut, just thread it on as best you can then plug weld. If using the stick is too hard may just use JB weld inside nut, just thinking out loud never tried it that way

yomax4 · Oct 7, 2011

ch47dpilot said:
I use a mig so not sure if this will work with a stick welder. Use a nut that the inside is smaller than the outside of the head. Plug weld inside the nut to the bolt head. then just use a socket on the nut to loosen bolt. The heat from welding usually helps break the old rust and stuff free. this works great it you break a bolt off inside something like an engine block. But for that use the same size nut, just thread it on as best you can then plug weld. If using the stick is too hard may just use JB weld inside nut, just thinking out loud never tried it that way

Ditto, Use mig tig or stick. It will work. Always does. Got a screw with a 1/2" head, use a nut with a 3/8 hole or less. Zap it a few times in the center and you will have it.

rcurrie · Oct 7, 2011

A stick welder usually works better, but is harder to do. I usually weld a washer first and then weld a nut to the washer. When the weld cools it shrinks and shrinks the broken fastener making it easier to remove. You probably could take those screws out with an impact driver though.

automech · Oct 7, 2011

I agree with the impact driver. Those screws are always super tight and need to be taken out with the hammer driver. They have not been ruined yet by the looks of them.

yomax4 · Oct 7, 2011

Worse case..You could touch the screws with a 312 Stainless Stick rod just enough to get penetration. Then you can take a Vise Grips and turn it out. Start the Arc and count 1001 and you are done. Leave the rod stuck to the bolt and clamp on the vise grip.

Kendrick · Oct 7, 2011

I doubt a impact would work. normal effort with a proper size screw driver and the metal just squished away. I was pushing aginst the end of the driver but the twisting force i was using was light. its crumbling like rotten wood for lack of a better descripton. oh well with luck the welding will melt the lock away even if it doesnt do much to the screw.

wow never would have thought to try a nut hope it will cover enough.. not sure if its to far recessed to do that. i know the truck will be a good canidate for that nut trick. stupid bolt is fairly easy to reach and is above the surface.

Kendrick · Oct 7, 2011

I should rephrase that i guess.. there are many faseners on this car that are failing through fatigue. i have had several non critical bolts especially where road salt and such gets to that just snapped off with normal effort. this is a 95 and 210k+ miles on it. engine is solid with some specifics i have to replace in the not so distant future. but a good car all the same.