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This shortcut is a tried and true method for those who know how to weld. Fully Threaded Bolt
Breaking the head off a bolt is a terrible scenario, but one many of us have encountered. There are various ways of removing the bolt once you find yourself in this unfortunate scenario, but if you can weld, that may be the quickest option.
A mig welder is the preferred tool for this job, but a stick welder (shown above) also does the trick. To start, s elect a nut with an inner diameter roughly the size of the stuck threaded bolt. Place the nut on the bolt and weld the inside of the nut to the broken top of the bolt. Then use a wrench to remove the nut and bolt together. You may have to attempt this numerous times for stubborn bolts, and it can help to drill into the bolt so the weld has more surface area to stick to.
Soak stuck bolts with PB Blaster or some other type of penetrating agent before you try the welding trick, as this might be all you need to free your bolt.
Timothy is a lifelong DIY enthusiast who is fixated on smart home tech, beautiful tools, and wrenching on his FJ62 Land Cruiser. He’s the DIY editor at Popular Mechanics and also the founder of the home improvement site, Charles & Hudson, the Webby-nominated family site, Built by Kids, and Tool Crave. When not working, you’ll find him on his board or bike enjoying the LA weather with his family and friends. Follow him on Instagram and Twitter.
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