Extract Broken bolts from deep hole NEW easy WAY

My bolt extractors are collecting dust. If you don't own a welder, this trick will pay for itself in one go. This is the first time I've ever shown this trick and I have never seen anyone else use the copper pipe. However, I'm sure someone out in the vast world has also come up with the idea as well and will quickly point it out to me. This is my go to method but there are still scenarios where a reverse drill bit would be my first choice as that is probably the quickest. However if those don't bite I move onto the welder/copper pipe.

With Mig or Flux:
Do it just like I show and don't burn away your copper. Go slow. On bolts over 1/2-5/8" you can also insert a steel pipe/tube inside your copper. Weld down the center and weld the steel pipe to the bolt. The copper will protect the threads. You don't need to fill the entire center to the top, just enough to bond the steel tube to the bolt. Twist out the steel tube/bolt assembly. This works best with large bolts.

With stick welder:
The flux helps insulate the sides. If the hole is large enough(1/2"+ bolt), insert a copper pipe to protect the threads and then a steel pipe inside the copper. You jamb the electrode down inside the steel and the rod will weld itself and the steel tube to the bolt. Throw a pipe wrench on the steel tube and pull it out. The larger the hole the better this method works. You can use this method with smaller bolts and just the copper but you have to be a GOOD stick welder.

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[cuttersgoose]

So after watching this video, I had a customer bring me a truck flywheel with a broken stud deep in the hole. Did exactly what you did in this video, and it came out very easy.. made 100$ ... so where do I send you cut?

[dirtbikedave]

This is what I love about youtube. People helping people. Thanks for the tip!

[somedudeRyan]

welder+ scrap heap = most of the specialized tools you'll ever need. awesome

[isaacplaysbass]

As soon as you showed the copper pipe it clicked - "Of course!" Why didn't I ever think about that!? Genius! I've used brass and copper so support flat weld repairs, but I've never put two and two together for deep bolt/stud repairs. Absolute genius. Thank you.

[garyrock]

This is what I love about YouTube, kind people like yourself taking the trouble to share knowledge. Thanks for the video.

[coreyg]

I learned about welding a nut over a broken bolt many years ago. Using the welder to remove a deep set broken bolt is a mind blowing game changer. So simple, yet so perfect. Well done man!

[lmtish]

I have been doing this for 35 years with a arc welder. It is great to have guys like you with a youtube channel to show stuff like this. Youtube is like a encyclopedia of knowledge and experience.

[frankpriolo]

I have been using the welded nut method to remove broken bolts for years. In 2008 I started working at a trucking company where the mechanics had been trying to drill out broken exhaust manifold bolts. When they screwed up the cylinder head trying to remove the bolt, they would replace the cylinder head. I showed the other mechanics they method and saved the company thousands of dollars. I couldn’t believe the other mechanics had never used that method before!

[archiebrown]

I have been doing weld bolt extraction for decades, but using a copper pipe to shield the threads was brand new to me. Excellent! No need to run a tap through a weld-damaged hole.

[flick]

Anybody that gives this a thumbs down has never had to remove a broken off recessed bolt. Thanks for the tips and, I had a sixtyfourford.

[falconeaterf]

I worked in a shop that rebuilt gas turbines from aircraft and power generators.
Lots of broken fasteners of all shapes and sizes. The welders were like magicians with their extraction techniques. Much respect.

[walter]

Been a machinist for about 55 years, and I'm embarrassed to admit that I've never seen this technique before. Not sure that it'd work for most situations, but I'm willing to try it out. Thanks for the new option.

[kencrawford]

Me and my brother have done it like this for over 20 years. Dont remember who had shown it to us but we also used one bad screw driver for dozens of bolts. Great job on this video!!!

[handyhandsome]

When welding out a broken bolt that sticks out, tack on a flat washer that fits the bolt.
This increases the inside diameter of the nut you can use. which allows you to add more heat to the bolt and the material it is in. The flat washer tends to protect the host material better, too.
It also helps to pour some water on the red hot nut, which shrinks the bolt even more, making it easier to extract.
When trying to extract an especially stubborn bolt out of steel, I have found that an overnight soak with a 10% Acetone/90% auto trans fluid mix really helps as well.

[.bronco]

For 20 years I've used aluminum soda cans. Cut a piece out roll I up and put it in the hole. Mig weld doesn't stick to the aluminum. I've used it to remove bolts on dozer tracks.

[FarmCraft]

And here I thought I'd seen all the broken bolt removal methods. That copper pipe is genius. The screwdriver is a cherry on top. Great stuff.

[eCitizen]

Wow, I've dealt with many bolts broken in deep holes and they are always frustrating and difficult. Sometimes leading to a drill out and special inserts. This is by far the BEST method I have ever seen for getting them out while protecting the threads. Thank you for the clever and efficient method. This is now my new goto method for getting this done.

[jmc]

This is the best tutorial out there for removing broken bolts.

[awgolasplowing]

Amazing! I have been wrenching and welding nuts on bolts for 20 years and never seen the copper tube trick...I will be using this at some point I'm sure. Thank you so much for sharing.

[rjwiderman]

Using a copper pipe shield was so great for protecting the aluminum threads. I will definitely use that in my shop work.