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How To Remove A Broken Bolt From Aluminum?

DIY Guide: How to Remove a Broken Bolt from Aluminum - Step by Step Tutorial

How To Remove A Broken Bolt From Aluminum? Removing a broken bolt from aluminum can be a difficult task, but with the right equipment and method, it is possible. Here’s how to extract a broken bolt from aluminum step by step:

  • Set up the area: Begin by using a degreaser to remove any dirt, grime, or oil from the area around the broken bolt. Remove any corrosion or rust that has formed around the bolt with a wire brush.
  • Drill a pilot hole: Drill a pilot hole into the center of the broken bolt with a drill bit slightly smaller than the diameter of the broken bolt. Drilling too deeply can damage the aluminum threads, so be careful.
  • To extract the broken bolt, use a bolt extractor of the same size as the hole. Insert the extractor into the hole and tighten it with a wrench or socket. The bolt will be gripped by the extractor and turned out.
  • If the bolt remains stuck, apply heat to the surrounding area to expand the aluminum and loosen the bolt. Heat the area around the bolt with a heat gun or propane torch, being careful not to overheat the aluminum.
  • Use a tap and die set: If somehow the threads on the aluminum have been damaged, you may need to repair them with a tap and die set. Clean out the damaged threads with a tap, then cut new threads into the hole with a die.
  • Replace the bolt: After removing the broken bolt and repairing the threads, you can replace it with a new one. To keep the new bolt from coming loose, use a thread-locking compound.
How To Remove A Broken Bolt From Aluminum

Note: It is crucial that the bolt removal tool is placed on the flat surface of the bolt and it fits into the right place. You can check this by slightly turning the bolt.

Final Verdict:

You should be able to remove a broken bolt from aluminum and restore your equipment to working order by following these steps. If you are unsure about any of these steps or the bolt is particularly stubborn, it is best to seek the assistance of a professional or a machine shop.

We hope that our guide on how to remove a broken bolt from aluminum helped you in doing the job yourself without any complications, Check out the More Tools  Cop from our Blog.



Alan Murry

Alan Murray is the founder and chief editor of Toolscop.com, a leading online resource for household tools reviews and recommendations. With a passion for all things related to lawnmowers, grinders, compressors, and other essential tools for maintaining a beautiful and functional home, Alan has built a reputation as a trusted expert in the industry. As the chief editor of Toolscop.com, Alan oversees a team of dedicated writers and researchers who work tirelessly to provide readers with the latest information on the best household tools available on the market. Through his informative and engaging reviews, Alan offers readers valuable insights into the features, performance, and reliability of the tools he writes about. Alan's writing style is approachable, easy to understand, and always backed by thorough research and hands-on testing of the products he reviews. He takes pride in his work and is committed to providing his readers with accurate and honest assessments of the tools he covers. Whether you're a homeowner looking to upgrade your tool collection or a professional seeking the latest innovations in the industry, Toolscop.com offers a wealth of knowledge and expertise that can help you make informed decisions and get the most out of your household tools. With Alan's leadership and dedication to quality, Toolscop.com has become a go-to resource for anyone looking to make smart purchasing decisions for their home tools.

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