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Last Updated on January 5, 2024 by bluefuze
Looking for ways to loosen or unscrew a rusted bolt? Our guide on how to remove a rusted bolt provides a variety of methods to help you get the job done.
How to Loosen a Rusted Bolt (or Remove a Rusted Bolt)
If you’re dealing with a stuck rusted bolt, the following tips can help you loosen it:
Scrape Excess Rust
If there’s a thick build-up of rust surrounding your fastener, your first move should be trying to scrape off as much of this rust layer as possible. A sturdy wire brush will do the trick.
Soak with Penetrating Fluid
Working smart is always better than working hard. As such, try soaking the rusted bolt with a high-quality penetrating spray to loosen it up.
Remember to be patient and give the penetrating material enough time to work its magic through the metal’s surface tension.
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Add More Torque
If you can’t loosen your rusted bolt using a regular pair of pliers or wrench, try using a tool with a longer handle such as a ratchet or a breaker bar. This will have you apply much less force to get the job done.
Start slowly turning the bolt and you should feel the resistance falter in no time.
Apply Heat
Metals expand upon heating and contract upon cooling. This simple fact can help you loosen a rusted bolt if you have a propane torch lying around.
Just apply heat to one of the bolt’s sides until it’s almost red. Once this happens, add some penetrating spray and the bolt should loosen up quickly.
What is a Stripped Bolt
When the head of a bolt gets rounded due to misuse or age, it’s called a stripped bolt. If a bolt has rounded edges, there’s no way for wrenches and sockets to grip it firmly and generate enough leverage to turn the bolt.
Typically, stripped bolts arise when there’s cross-threading, rust build-up, or when an incorrect wrench or socket size is used on the bolt.
How to Unscrew a Stripped Bolt
If you’re looking into ways to unscrew a stubborn stripped bolt, the following tips can help you get things done:
Spray Penetrating Fluid
Spray the stripped bolt with a high-quality penetrating fluid. Soak it well and it should loosen up after a short while.
Remember to allow the penetrating fluid enough time to work its magic through the metal’s surface tension and break up the bonded parts of the bolt. From there, the bolt should be quite easy to unscrew.
Screw the Bolt Back In then Out
If the bolt was moving, even if it’s for the slightest bit, before starting to strip, screw it back in then back out with a dash of penetrating fluid if available.
Use Locking Pliers
Using locking pliers with enough pressure can generate enough leverage to turn and unscrew the bolt.
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Use a Smaller Wrench or Socket
The bolt may be so rounded that it can fit a smaller wrench or socket on it using a hammer. If this happens, you’ll get more grip to unscrew the bolt.
Apply Heat
Apply heat to one of the bolt’s sides until it’s almost red. Once this happens, add some penetrating spray so that the bolt loosens up enough to unscrew.
Try a Hammer
Some force can break up the bond between the bolt and the rust layer, and what better tool to do that than a hammer? Tap the bolt intentionally but lightly to avoid ruining the threads.
Consider Extraction Kits
Bolt extractor kits are available on the market and are specifically made for this purpose. They often include teethed tips that latch onto the metal to create a secure grip.
Drill the Bolt Out
As a last resort, you may have to drill the bolt out. To do this, you should be capable of handling power tools and own the right bits for the task.
Don’t rush the process and begin using a small bit. Then, gradually widen the hole until the stripped bolt loosens or breaks.
How to Cut Off a Bolt
Cutting off a bolt is a sure way to remove it no matter the way it got stuck in the first place. Here’s how to perform relief cuts:
- Make a couple of cuts through the head of the bolt.
- Use a hammer or a chisel to hit the head of the bolt. This will cause it to split, consequently relieving the tension.
How to Remove a Cross Threaded Bolt
There are various approaches to removing a cross-threaded bolt. Go through the following tips to find the right one for your situation:
Use Blunt Force
There’s a couple of ways you can do this:
- Strike the head of the bolt with a hammer or chisel.
- Hit the head of the bolt using an impact gun or wrench.
Apply Heat
Apply heat to one of the bolt’s sides until it’s almost red-hot. Once this happens, add some penetrating spray so that the bolt loosens enough for you to remove.
Perform Relief Cuts
Performing relief cuts is a sure way to remove a bolt no matter the way it initially got stuck. Here’s how to perform relief cuts:
- Make a couple of cuts through the head of the bolt.
- Use a hammer or a chisel to hit the head of the bolt. This will cause it to split, consequently relieving the tension.
“Rock” the Fastener
If you can move the bolt, even for a tiny bit, then try to “rock” it. This means screwing the bolt back in then back out. Spray some of the penetrating fluid if available.
Use a Drill
You may have to drill the bolt out. To do this, you should be capable of handling power tools and own the right bits for the task.
Don’t rush the process and begin using a small bit. Then, gradually widen the hole until the stripped bolt loosens or breaks
Hit It with a Hammer
Applying some force can break up the bonds between the bolt and the rust layer, and what better tool to introduce such force than a hammer?
Simply tap the bolt intentionally but lightly to avoid ruining the threads. This method has a moderate success rate, but it’s particularly useful if the fastener is out in the open.
Use an Extraction Kit
Bolt and nut extractor kits are readily available on the market. They’re particularly made for this purpose and often come with teethed tips that latch onto the metal to create a secure grip.
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How to Remove a Cross Threaded Nut
To remove a threaded nut, you can use the same methods we discussed in the section above. That being said, you can weld a new bolt or nut onto the old one if the latter is beyond salvaging.
All you need to do is grab a slightly larger bolt and nut then tack weld them to the current bolt body. Once welded, you should add weld to fill the nut then spread a bead at the meeting point between it and the bolt body.
Wrap Up
There you have it, a complete guide on how to remove a rusted bolt or nut.
Be sure to also check out my other posts on power tools:
