When faced with a rounded bolt head, it can be a frustrating experience that stalls a project or repair. Rounded bolts can occur due to wear and tear, using the wrong size socket or wrench, or simply due to rust.
However, there are effective methods to remove these stubborn bolts without causing damage to the surrounding materials. In this guide, we will explore various techniques and tools for how to remove a bolt with rounded head, ensuring you can continue with your work with minimal disruption.
Understanding Rounded Bolt Heads
A rounded bolt head occurs when the edges of the bolt become worn down, preventing standard tools from gripping effectively. This can happen for several reasons, including improper tool use, overtightening, or exposure to harsh environments that lead to corrosion.
Understanding the characteristics of rounded bolt heads is crucial for devising a suitable removal strategy. It’s important to assess the extent of damage: if the head is merely rounded but still has some usable grip, certain techniques may restore your ability to remove it.
On the other hand, if the head is severely rounded or damaged, more aggressive approaches might be necessary. By recognizing the state of the bolt head early on, you can select the appropriate tools and techniques, saving time and reducing the risk of further damage.
Tools and Materials Needed
To successfully remove a bolt with a rounded head, it’s essential to have the right tools and materials on hand. Here’s a list of items that will aid in the removal process:
- Penetrating Oil: To loosen rust and corrosion around the bolt.
- Rubber Bands: Can be placed over the bolt head to enhance grip for socket or wrench.
- Bolt Extractor Set: Specially designed tools that can grasp and remove rounded bolts.
- Pliers: Needle-nose or locking pliers can provide additional grip on the rounded head.
- Hammer: To gently tap the extractor or other tools into place if necessary.
- Drill: In more severe cases, drilling a hole into the bolt can create a new grip.
- Screw Extractor: A tool for removing bolts when other methods fail.
- Safety Goggles and Gloves: To protect your eyes and hands during the removal process.
Having these tools and materials ready before starting ensures a smoother removal experience.
10 Methods How to Remove a Bolt with Rounded Head
Using a Bolt Extractor Set
A bolt extractor set is specifically designed to remove damaged or rounded bolts. These sets typically include extractors that are tapered and have reverse-threaded patterns, which grip the bolt head as you turn them counterclockwise. To use a bolt extractor, first select an extractor that fits the size of the bolt.
Then, use a drill to create a small hole in the center of the rounded bolt head, ensuring it is deep enough for the extractor to engage. Insert the extractor into the hole and turn it counterclockwise with a wrench or ratchet. The reverse threads will grip the bolt and help you remove it. Bolt extractors are effective because they provide a strong grip on damaged heads and are designed specifically for this purpose.
Applying Penetrating Oil
Penetrating oil can be a crucial step in loosening a rounded bolt before attempting other methods.
Penetrating oil, such as WD-40 or PB Blaster, seeps into the threads of the bolt and can help break the rust or corrosion that may be causing the bolt to stick. To use penetrating oil, spray it generously onto the bolt head and surrounding threads. Allow it to sit for at least 10-15 minutes to penetrate and loosen any rust or debris. This step is particularly useful when dealing with old or rusted bolts, as the oil can make the removal process easier and reduce the risk of further damaging the bolt or surrounding components.
Utilizing a Vice Grip
A vice grip, or locking pliers, can be an effective tool for removing a rounded bolt head. To use this method, adjust the vice grip to fit snugly around the rounded bolt head. Once in place, lock the vice grip to ensure a firm grip on the bolt.
With the vice grip securely clamped onto the bolt, turn it counterclockwise to loosen and remove the bolt. The vice grip’s serrated jaws provide a strong hold on the bolt head, even when it is rounded, allowing you to apply sufficient torque to extract it. This method is particularly useful when the rounded bolt head is still relatively intact.
Drilling Out the Bolt
Drilling out a rounded bolt is a more aggressive method but can be effective when other techniques fail. Begin by selecting a drill bit slightly smaller than the diameter of the bolt. Drill a hole into the center of the rounded bolt head, ensuring that you drill straight and avoid damaging the surrounding area.
Once you have drilled a sufficient hole, use a bolt extractor or a left-handed drill bit to remove the bolt. The left-handed drill bit, which turns counterclockwise, can sometimes grip the bolt and unscrew it as you drill. This method requires precision and care to avoid damaging the threads or surrounding components.
Using a Hammer and Chisel
A hammer and chisel can be used to remove a rounded bolt by creating a new grip point. Position the chisel on the edge of the rounded bolt head and tap it gently with a hammer to create a notch or groove.
Once a groove is established, use the chisel to pry and turn the bolt head counterclockwise. This method relies on creating a new grip point on the bolt head and can be effective if the bolt is not overly damaged. Care should be taken to avoid damaging the surrounding area or causing further rounding of the bolt head.
Applying Heat
Applying heat to a rounded bolt can help loosen it by expanding the metal and breaking any rust or corrosion. To use this method, heat the bolt head with a propane torch or similar heat source for several minutes.
The heat will cause the metal to expand, which can break the bond between the bolt and the surrounding threads. After heating, allow the bolt to cool slightly before attempting to remove it with a wrench or vice grip. This method can be particularly effective for rusted bolts but requires caution to avoid overheating and damaging surrounding components.
Using a Screw Extractor
A screw extractor, or easy-out, is a tool designed to remove damaged or rounded fasteners. To use a screw extractor, first drill a small hole into the center of the rounded bolt head. Choose a screw extractor that fits the size of the hole you’ve drilled and insert it into the hole.
The extractor’s tapered design will grip the inside of the bolt head as you turn it counterclockwise with a wrench. This method is effective for bolts that are too damaged for traditional tools but requires precision in drilling and handling the extractor.
Using a Hammer and Socket
If the rounded bolt head is not too severely damaged, you may be able to use a hammer and socket to remove it. Select a socket that is slightly smaller than the rounded bolt head.
Tap the socket onto the bolt head with a hammer to force it onto the damaged surface. Once the socket is securely in place, use a ratchet or wrench to turn it counterclockwise. The socket’s grip can help to loosen the bolt, particularly if the head is only slightly rounded. This method is effective when there is enough remaining surface on the bolt head to engage with the socket.
Tapping the Bolt with a Punch
Tapping the rounded bolt head with a punch can help to create a new grip point and break loose any rust or corrosion. Position a punch or a small chisel on the edge of the bolt head and gently tap it with a hammer. The goal is to create a notch or groove that will allow a wrench or vice grip to engage more effectively. This method can be combined with other techniques, such as applying penetrating oil or using a vice grip, to improve the chances of removing the bolt.
Using a Welding Method
For bolts that are extremely rounded or damaged, welding a nut onto the bolt head can provide a new grip point for removal.
To use this method, first, place a nut over the rounded bolt head. Using a welder, weld the inside of the nut to the bolt head. Allow the weld to cool and solidify, creating a strong connection between the nut and the bolt. Once the weld has cooled, use a wrench to turn the nut counterclockwise, which will unscrew the bolt. This method requires welding skills and equipment but can be highly effective for severe cases of rounded bolt heads.
Conclusion
In conclusion, removing a bolt with a rounded head requires a variety of techniques and tools, each suited to different levels of damage and accessibility.
Whether using a bolt extractor set, applying penetrating oil, or resorting to more aggressive methods like drilling or welding, each approach has its own advantages and considerations. Thanks for reading, and we hope this has given you some inspiration on how to remove a bolt with rounded head!
