How do you remove a damaged or stuck hexagonal screw bolt?

Removing a damaged or stuck hexagonal screw bolt can be challenging, but there are several methods you can try.

Assess the Situation: Determine the extent of the damage and the reason why the bolt is stuck. It could be due to corrosion, over-tightening, or physical damage.

Apply Penetrating Oil: Spray a generous amount of penetrating oil, such as WD-40 or PB Blaster, onto the bolt threads. Allow the oil to penetrate for several hours or overnight to help loosen the bolt.

Heat the Bolt: If the bolt is still stuck after applying penetrating oil, use a heat source, such as a propane torch, to heat the area surrounding the bolt. Heat helps to expand the metal, breaking the bond between the threads.

Use Impact: If the bolt is accessible, try using an impact wrench or a manual impact driver to apply sudden rotational force. The shock can help break the bolt free.

Use a Bolt Extractor: If the bolt head is damaged or stripped, you can use a bolt extractor tool. Drill a small hole into the center of the bolt head, then insert the bolt extractor and turn it counterclockwise. The extractor bites into the bolt, allowing you to remove it.

Cutting or Grinding: As a last resort, you may need to cut or grind the bolt off. Use a hacksaw, reciprocating saw, or angle grinder to carefully cut through the bolt. Be cautious not to damage the surrounding components.

Drill Out the Bolt: If all else fails, you can drill out the hexagonal screw bolt. Start with a small drill bit and gradually increase the size until the bolt is completely removed. Exercise caution to avoid damaging the threads of the surrounding material.

Tap and Die Set: After removing the damaged bolt, you may need to re-tap the threads or use a thread repair kit to restore them.

Remember to wear appropriate safety gear, such as gloves and eye protection, when attempting to remove a damaged or stuck bolt. If you're unsure or uncomfortable with any of these methods, it's best to seek professional assistance.

PREV：Choosing Between Full Thread Screws and Partial Thread Screws for Different Fixing Positions
NEXT：What is the difference between 304 and 316 stainless steel screws?