Ideas to remove sheared bolt?

[George2615]

All good suggestions.
I'd try cutting a slot, then heat the surrounding area and use the impact driver. If that doesn't work then have a nut plug welded to the remaining stud and back it out.

 

[Redbug]

I think I would try using a reverse hand drill bit. Sometimes once you go far enough the bolt will unscrew with the drill bit. If that does not work, you have the hole to use for the extractor. If there is still a bit of bolt head left, why not try this: IRWIN Bolt Extractor Set, 5-Piece (3942) - Drill Bits - Amazon.com

 

[radios1]

first, you need a flat spot on the bolt, so the bit don't wander, then, you can use a dremel with a pointed bit to make a flat spot, you can use the side of a small ball bit too, which won't wander on you. then, use a small drill bit, and work your way up to a size that will work with an easy out, don't make the hole so big that it will cut the threads, though..

 

[zzvyb6]

A USA made ViceGrips ought to be able to bite down on that bolt if its not totally rusted in there. Grid a nice flat, sharp edge on them and go to work. I'd heat it cherry to relax the corrosion and spin it out. You might have to heat it anyway to drive the cylinder pin out.

 

[Industrial Toys]

There are a lot of options. It matters how much you care about appearance and butchering your equipment.

So how did the head shear off? If the bolt is in there that good that the head sheared off trying to remove, then any ideas of cutting a slot is not going to be worth the time spent on it.

Easy outs are not great on seized or stretched bolts.

 

[FTG-05]

Sounds a perfect excuse to buy a welder.

 

[Industrial Toys]

I don't think it would be my first choice for a first time welding experience. That takes a little experience, if you ask me. Personally, I use a washer, with nut welded on after, or flat metal with a hole drilled in it, like a wrench. I don't like trying to weld down into a (thick) nut.

 

[radios1]

There are a lot of options. It matters how much you care about appearance and butchering your equipment.

So how did the head shear off? If the bolt is in there that good that the head sheared off trying to remove, then any ideas of cutting a slot is not going to be worth the time spent on it.

Easy outs are not great on seized or stretched bolts.

if you use a large enough one they usually work, and another way is to make the hole as large as possible without damaging the threads, then use an air file Air File to make 4 slits inside the bolt, then use a chisel on the out side of the bolt to collapse the pies into the center, then remove them with needle nose pliers, that method has worked for me before!!..

 

[Industrial Toys]

In one sense, a fluted easy out is spreading the bolt making extraction harder than it might need to be. Again, it all matters why the bolt is stuck in there. If it never had lubrication from day one (typical) it can be very challenging.

 

[mcfarmall]

If the third picture is a photo of the bolt head that got twisted off, then it's the funniest looking bolt I've ever seen. Looks to me like a piece of all-thread with a jam nut spun down a few threads to lock it in place.

Anyhoo, you are going to need lots of heat and a set of left hand drill bits.