Coming across a stripped bolt can be frustrating, but it’s all a part of becoming a skilled wrencher. Learning how to remove a stripped bolt is the first step in honing your craft.
Once you’ve learned the art of bolt removal, other wrenching tasks will become much easier! With patience and perseverance, you’ll be able to tackle any project.
This guide will teach you how to remove a stripped bolt using different methods and will outline the common causes of a stripped bolt so you can avoid them in the future.
What Is A Stripped Bolt?
A stripped bolt is one whose head has been rounded due to misuse or normal wear and tear.
Round edges prevent sockets and wrenches from grabbing the bolt and applying leverage to turn it.
Stripped bolts frequently happen with cross-threaded bolts, rusted bolts, and bolts that have been used with the wrong size socket or wrench.
Common Causes In Detail
There are four common causes of a stripped head on a corroded bolt.
They have been outlined in detail below so you can avoid making the mistakes that many wrenchers make and also give you some insight into how to fix them.
User Error
Sometimes, the reason for a stripped bolt is simple user error in some way or another.
People are more likely to rely too heavily on common sense than actual knowledge when things seem straightforward, like when trying to find a wrench that will fit into a seized bolt.
A wrench that seems as if it fits the bolt may not actually be the perfect fit. You need the exact fit to avoid a stripped bolt.
Low Quality Materials
While user error is a common cause of a stripped bolt, it can also be down to a manufacturing defect or the result of using low quality parts.
Even cheaper options should be able to stand up to everyday use. However, not all manufacturers sell bolts that are made from decent, durable materials.
A lower quality bolt won’t be protected against aging, weather, and even the slightest user error. In most cases, they will eventually break long before they should.
Mismatched Material Grades
Problems can also arise when the bolt and the fastener are made of different materials and grades.
For instance, some fasteners have a layer of galvanized protection to keep them from rusting, but this layer also increases their size, so your bolt won’t fit correctly.
The fit will be too tight, and this might cause it to seize and get stuck.
Over-Tightening
You can also cause a stripped bolt by over-tightening it, making it much harder to remove than a stripped screw.
Over-tightening weakens the metal of the bolt and can even cause the bolt head to snap off completely, which is a serious problem.
Everything You Might Need
There are a couple of different ways to remove a stripped bolt, and you may have to try more than one.
While you might not need all of these tools, it would be helpful to have them just in case one method doesn’t work or for use on future projects.
- Penetrating fluid, like PB Blaster
- Normal socket set
- Extraction socket set
- Drill and drill bits
- Blowtorch
- Bolt extractor kit
- Dremel or similar cutting tool
- Flathead screwdriver
- Locking pliers
Keep all these tools close by on a flat workspace so that they’re easily accessible and away from any children or pets that might be looking to give you a thoughtful, but unsafe hand!
Different Removal Techniques
As we’ve previously mentioned, you might need to try a few different methods to remove that pesky stripped bolt. Give them a try and see which one works best!
Locking Pliers
Every homeowner should have a set of locking pliers in their garage.
When it comes to a stripped bolt, the teeth of your locking pliers may be able to offer enough grip to turn the bolt if you can apply enough force to it.
Extraction Socket
Not everyone will have this, but there are sockets called extraction sockets that are made specifically to have a stronger grip on stripped bolts.
It’s worth a try, but it doesn’t always work.
Smaller Socket Or Socket Wrench
In some instances, the bolt will be sufficiently rounded that you may be able to fit a smaller wrench or socket on it.
Using a hammer with your wrench on the bolt should increase the grip and cause the bolt to come loose.
Penetrating Fluid
Penetrating fluid is designed to dissolve rust and dirt that holds the stripped bolt in place.
It may be possible to loosen the bonded areas and lubricate the bolt by applying PB Blaster to the stripped bolt.
Screw It In
If you were able to move it even a tiny bit before it started to strip, then try screwing the bolt in and back out again.
Repeating the action a few times might finally break the bolt free. It’s wise to use penetrating fluid with this method too.
Heat
Heating the stripped bolt at a high temperature could break the bolt free. Using a blowtorch, you can apply plenty of heat so that the metal expands and contracts.
This might allow the stripped bolt to start turning. This is also a good method for removing a frozen bolt.
Hammer
A small amount of shock force may be enough to fracture the link between the rust and the bolt.
Start out by lightly tapping while making deliberate movements. If you’re not careful, you could make it worse by destroying the threads.
Drill It Out
In the worst cases, you might be forced to remove the bolt by drilling. Do this only if you are entirely confident using your power tools and have the right drill bit.
Take your time, begin with only a small amount, and gradually enlarge the hole until the bolt becomes loose or is split in two.
This is also a good way to remove a broken bolt.
Weld On A New Bolt Head
If you have a welder, then you could use it on the stripped bolt. However, this is quite a big task. For very stubborn bolts, you can weld a new squared-off bolt head onto the bolt.
Doing this should give you the grip necessary to remove the stripped bolt, however, it is possible that you’ll just round the new bolt head as well.
Cut A Slit
Make a slit in the bolt head using a Dremel tool or another type of cutter or grinder.
Then, attempt to use that leverage to free the bolt with a flathead screwdriver or something similar that will fit into the slit.
Bolt Extractor Kit
Some manufacturers produce bolt extraction kits that are designed exclusively to remove tough stripped bolts.
They usually include teethed, cone-like tips that can dig into the metal and give you a better grip for removing it.
Final Thoughts
If none of these methods work for you, then it might be time to call in a professional.
Of course, you want to avoid this, but sometimes it is the best solution, especially if you don’t have the right equipment or if the bolt is particularly stubborn.
In most cases, one of these methods will work for you, so try them out and see if you can get rid of that annoying stripped bolt!