Probably a stupid idea…

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   I have a bolt broken off flush with the hole, in a cast iron housing.  It’s a hard bolt, can’t drill it with the tools on hand but looking into that. It has blue Loctite on it. 

Actually had two broken ones. I welded a bolt to the first one and it worked like a charm. I’m having a heckuva time getting the second one out. Not enough hands and access and….whatever to get something welded on strong enough. 

Anyway, here’s my brain dead idea. What would happen if I cranked the current up and stuck a bolt directly into the stinger?  Would save a hand. Might work, might not. What could it hurt?

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Tbone95 Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Access Joined: 31 Aug 2012 Location: Michigan Points: 12392	Post Options Post Reply Quote Tbone95 Report Post Thanks(0) Quote Reply Topic: Probably a stupid idea… Posted: 3 hours 23 minutes ago at 7:14am
	I have a bolt broken off flush with the hole, in a cast iron housing. It’s a hard bolt, can’t drill it with the tools on hand but looking into that. It has blue Loctite on it. Actually had two broken ones. I welded a bolt to the first one and it worked like a charm. I’m having a heckuva time getting the second one out. Not enough hands and access and….whatever to get something welded on strong enough. Anyway, here’s my brain dead idea. What would happen if I cranked the current up and stuck a bolt directly into the stinger? Would save a hand. Might work, might not. What could it hurt?

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NEVER green Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Access Joined: 28 Feb 2013 Location: MN. Points: 9249	Post Options Post Reply Quote NEVER green Report Post Thanks(0) Quote Reply Posted: 1 hour 55 minutes ago at 8:42am
	Have you tried welding a thick washer to it then a nut to the washer?? The washer gives you more access to weld.
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SteveM C/IL Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Access Joined: 12 Sep 2009 Location: Shelbyville IL Points: 8931	Post Options Post Reply Quote SteveM C/IL Report Post Thanks(0) Quote Reply Posted: 1 hour 48 minutes ago at 8:49am
	When I have broken off bolts like that I weld directly on broken bolt and build up end till I can get a Visegrip on it. Sometimes it takes several tries after twisting off. Stick welder ( all I had till recently). 6013 Blob and chip.blob and chip. Heat gain will solve loctite and chipping usually helps loosen. Mostly done on Cat ex manifold studs 3/8. Nice thing about being in cast is cast don't weld well to steel so you don't have to worry about welding stud to hole. If you don't have room to work.....you have some decisions to make As far as using a bolt vs a weld rod...think you're going to find huge arc splatter with no control over puddle. Ever had a rod missing flux? Same result Edited by SteveM C/IL - 1 hour 36 minutes ago at 9:01am

DanielW Members Profile Send Private Message Find Members Posts Add to Buddy List Silver Level Joined: 19 Sep 2022 Location: Ontario Points: 295	Post Options Post Reply Quote DanielW Report Post Thanks(0) Quote Reply Posted: 1 hour 22 minutes ago at 9:15am
	You say you 'welded a bolt' to it. Did you actually weld a 'bolt' to it? That would be tricky. More commonly you weld a nut to it - welding through the middle. I'd give that a try if you haven't yet. Lots of heat: You need good penetration into that hardened bolt for the first second or two of welding. Everything after that is just building up and not adding any more penetration into the original bolt, and thus not really helping too much. I have better luck using MIG with it really cranked up and higher gas flow to avoid porosity. When using stick on such a small, short, quick weld, it's pretty much impossible to get the flux fully out and avoid any porosity. With such a small area, you need the weld to be as perfect as possible. Sounds like loc-tite 243 or equivalent on there. Once welded and cooled, make sure you use a torch to heat the surrounding area uber hot before trying to spin it out. Edited by DanielW - 1 hour 20 minutes ago at 9:17am

AC7060IL Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Joined: 19 Aug 2012 Location: central IL Points: 3649	Post Options Post Reply Quote AC7060IL Report Post Thanks(0) Quote Reply Posted: 1 hour 21 minutes ago at 9:16am
	Tbone95, your bolt as electrode will probably fail from being too porous of a weld (many tiny holes)? The bolt has no flux coating to gas shield & produce a good solid weldment. Probably best to keep trying, using a thinner welding rod(6013,etc?). Maybe go to harborFreight & buy thinnest weld rods? Then without any flat washer, nut, bolt, etc,,, USING ONLY WELDING ROD, weld onto broken bolt to HEAT IT & BUILD IT UP.. If build up is successful, then try welding flat washer, nut to it for easier removal. Failed welding rod attempts are kinda good because each Consecutive heat treatment is your friend to loosen corroded threads of broken bolt. Yes naked bolt weldings are failed attempt too, but it’s welds are not good ones. Edited by AC7060IL - 1 hour 18 minutes ago at 9:19am

Tbone95 Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Access Joined: 31 Aug 2012 Location: Michigan Points: 12392	Post Options Post Reply Quote Tbone95 Report Post Thanks(0) Quote Reply Posted: 24 minutes ago at 10:13am
	Yes I actually welded a bolt to it. My thought just went there. Worked once! A nut sounds like a good idea. The washer, maybe, though not a large OD so might be tricky to find one that would work. Doesn’t help that my helmet sucks. I’ll keep hacking at it. Thanks for talking me out of the bolt electrode idea!

Ray54 Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Access Joined: 22 Nov 2009 Location: Paso Robles, Ca Points: 4852	Post Options Post Reply Quote Ray54 Report Post Thanks(0) Quote Reply Posted: 17 minutes ago at 10:20am
	As others have said a failed attempt is just another heat cycle to help break the loc-tight and or rust holding the broken bolt. The down side of the arc weld is cleaning the slag out from the failed weld before the next attempt. I think the real help of starting with a flat washer is the added heating on the broken bolt. It is one welding cycle to fill the flat washer. Clean slag, then weld a nut on. Even though the nut will be full of slag and not a real good weld. Fill the nut full of weld, even more heat sinking down the broken bolt. Another thing is have patients after the weld. At the least let it cool until you can keep your hand on it. Even better go work on something else for several hours. Taking cast iron radiator tanks apart I have weld more than a 1/2 dozen nuts on some. But I have never had one that did not come out on the 6 or so radiators I have taken apart.