Removing a stripped bolt from metal can be a frustrating and time-consuming task, but with the right tools and techniques, it’s entirely manageable. Stripped bolts occur when the head of a bolt becomes worn or damaged, making it difficult to grip with standard tools.

This situation often arises from over-tightening, rust, or improper tooling. Fortunately, there are several methods you can use to tackle the problem effectively while minimizing the risk of further damage to the surrounding material.

In this blogpost on how to get a stripped bolt out of metal, we’ll discuss some of the most effective methods and tips for removing stripped bolts.

Tools Required

Before attempting to remove a stripped bolt, it’s essential to gather all the necessary tools. These include:

Pliers or Vice-grip Locking Pliers:

These tools provide a strong grip on the bolt and can be used to turn it counterclockwise.

Drill:

A drill with a left-hand bit is useful for drilling through the center of the stripped bolt, allowing you to use an easy-out tool or tap set to remove it.

Easy-Out Tool:

This specialized tool features a reverse-threaded shaft that digs into the inside of the bolt as you turn it counterclockwise. This method is best suited for bolts with damaged heads that can no longer be gripped by pliers or vice-grip locking pliers.

Tap Set:

If only part of the head of the bolt remains, using a tap set can help create new threads to remove the bolt.

Heat Gun:

In cases where rust or corrosion is causing the stripping, a heat gun can be used to heat up and expand the metal around the bolt, making it easier to remove.

Penetrating Oil:

If rust or corrosion is present, spraying some penetrating oil around the bolt can help loosen it and make it easier to remove.

8 Step-by-step Guidelines on How to Get a Stripped Bolt Out of Metal

Step 1: Assess the Situation 

Before deciding on a method to remove the stripped bolt, take a moment to thoroughly assess the situation. Examine the bolt’s condition and determine the extent of the damage to the head. Identify if rust, corrosion, or dirt is contributing to the difficulty in removal.

Evaluate the surrounding area to ensure that attempts to remove the bolt won’t cause unintended damage to the material or adjacent components. Proper assessment will help you choose the most suitable tools and techniques for safe and effective removal.

Step 2: Spray Penetrating Oil 

If rust or corrosion is making the bolt difficult to remove, applying penetrating oil can be highly effective. Spray a generous amount of penetrating oil around the base of the stripped bolt, ensuring it seeps into the threads. Allow the oil to sit for at least 10-15 minutes to give it time to break down the rust and loosen the bond between the bolt and the surrounding metal.

For stubborn bolts, you can repeat this process multiple times for better results. Once the oil has had time to work, try turning the bolt with pliers or a vice-grip. This step often serves as a critical foundation in freeing stuck bolts with minimal risk of damage.

Step 3: Heat up the Bolt 

If penetrating oil alone is not enough to loosen the bolt, using heat can often do the trick. By heating up the surrounding metal, you expand it, which can create extra space between the bolt and its seat. This method is particularly effective when dealing with older bolts or those that have corroded over time.

Using a heat gun, apply steady heat around the base of the stripped bolt without getting too close to any plastic or rubber components that may be nearby. Once heated, try turning the bolt again with pliers or vice-grip locking pliers.

Step 4: Use Pliers 

If you are lucky enough to have a bolt with a partially intact head, gripping it with pliers or vice-grip locking pliers may provide enough leverage to remove it. Make sure to use pliers that are large enough to fit around the bolt’s head and have serrated jaws for better grip. Grab onto the bolt as tightly as possible and turn counterclockwise.

If there is not enough of the head left to get a good grip on the pliers, try using an adjustable wrench instead.

Step 5: Try Vice-grip Locking Pliers 

Vice-grip locking pliers are similar to regular pliers but feature a locking mechanism that allows them to stay in place without requiring constant pressure from your hand. They also provide a stronger grip on the bolt than regular pliers, making them ideal for removing stubborn, stripped bolts.

To use vice-grip locking pliers, adjust the jaw opening to fit snugly around the bolt’s head and then lock it in place. Use your opposite hand to hold onto the pliers’ handle and turn counterclockwise.

Step 6: Drill into the Bolt 

If none of the above methods are successful in removing the stripped bolt, drilling may be necessary. Using a drill with a left-hand bit, carefully drill through the center of the bolt. The reverse rotation of the bit will help loosen and remove material from inside the bolt while you drill.

Once the bit has gone through the bolt, use an easy-out tool or tap set to extract it.

Step 7: Use an Easy-Out Tool 

An easy-out tool is specifically designed for removing stripped bolts. It features a reverse-threaded shaft that digs into the inside of the bolt as you turn it counterclockwise. To use this tool, insert it into the hole created by drilling and grip onto its handle.

Turn counterclockwise with steady pressure until the bolt starts to move and then slowly remove it from the material.

Step 8: Remove Using a Tap Set 

If only part of the head of the bolt remains, using a tap set can help create new threads to remove it. Begin by selecting a tap that is slightly smaller than the bolt’s diameter and insert it into the hole created by drilling.

Rotate the tap in a counterclockwise direction, applying steady pressure until you feel resistance. Then, turn clockwise to create new threads inside the bolt. Once you feel the bolt loosen, continue turning counterclockwise until it comes out completely.

Following these step-by-step guidelines on how to get a stripped bolt out of metal can help you effectively remove a stripped bolt from metal without causing further damage. It’s important to take your time and carefully assess the situation before attempting any removal methods, as using the wrong technique or tools can lead to more significant issues or damage. In some cases, it may be best to seek professional help if the stripped bolt cannot be removed safely and effectively on your own.

Frequently Asked Questions

Q1: Can You Use Wd-40 as a Penetrating Oil?

A: While WD-40 is commonly used as a lubricant, it can also act as a penetrating oil in some cases. However, its effectiveness may vary depending on the severity of the rust or corrosion present on the bolt. It is recommended to use a specifically designed penetrating oil for better results.

Q2: Should I Use Heat on Plastic or Rubber Components?

A: No, it’s not advisable to use heat near plastic or rubber components as they can easily melt or become damaged. Make sure to protect these materials while using heat around the bolt. If possible, try using an alternative method that doesn’t involve heat.

Q3: What if the Easy-Out Tool Breaks Inside the Bolt?

A: This can be a frustrating situation, but it’s important not to panic. If this happens, you can try drilling into the broken tool and removing it with needle-nose pliers or tweezers. If this proves to be unsuccessful, it may be best to seek professional help in extracting the broken tool and bolt.

Q4: Can I Use an Impact Wrench on Stripped Bolts?

A: An impact wrench can provide a significant amount of torque, which may be useful in removing stripped bolt. However, it’s essential to use caution when using an impact wrench, as it can also cause damage to the surrounding material if not used correctly. Make sure to read and follow the manufacturer’s instructions before attempting this method.

Conclusion 

Removing a stripped bolt from metal can be a challenging task, but with the right tools, techniques, and patience, it is entirely achievable.

By following the outlined step-by-step guidelines on how to get a stripped bolt out of metal, you can tackle most situations effectively while minimizing the risk of further damage to the surrounding material. Always start with the least invasive methods, such as applying penetrating oil or using pliers, and progressively move to more advanced techniques like drilling or using an easy-out tool if needed.

Proper preparation and assessment of the situation are crucial to ensuring success. Remember, if the bolt proves too difficult to remove or if you are unsure about the methods, seeking professional assistance is always a safe and reliable option.