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Hardened bolts

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DanielW View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DanielW Quote  Post ReplyReply Direct Link To This Post Posted: 28 Jan 2025 at 10:02am
Usually drilling a bolt out is the very last option you should try for stuck/seized/broken bolts, because it's so time-consuming (and bit-consuming) and seldom works well. The nut welding trick and/or oodles of heat and spinning with a punch are usually more successful. But it sounds like you have no choice but to drill in your case

What I've had luck with in those situations involves heat and an oversized bit to drive in there. Once you drill a decent-sized hole through it, get it red hot so it's soft, and drive something oversized into the hole while it's nice and soft. For smaller fasteners a Torx bit a little larger than the hole works well because the torx bit cuts its own 'teeth' into it and gets lots of grip. For large fasteners a large hex key, or even a socket extension ground flat-ish works. Something that will cut its own grooves/teeth. Then try spinning it out while red hot. If that doesn't work, let it air cool with your torx bit/whatever in there, then heat the surrounding area red hot (properly red hot) and try spinning out. You'd be surprised at how easy they can spin out when it's nice and toasty red, vs. how seized or stiff they still are when it's only a dull/colder red.

Whatever you do however, don't try twisting too hard and break off whatever tool you've driven in there. Then you'll have an uber-hard piece of tool steel in there that will be impossible to drill through.


Edited by DanielW - 28 Jan 2025 at 10:03am
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DiyDave View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote DiyDave Quote  Post ReplyReply Direct Link To This Post Posted: 28 Jan 2025 at 2:37pm
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