Thread: Best tool for removing broken bolts?

Ok, so I fix restaurant and bakery equipment for a living! I run across a fair amount of rusted equipment, and, of course, the occasional bolt head will break off while removing a panel, top, or maybe a motor or something! Anyways I had a set of easy outs I bought about 20 years ago, and about 5 years ago I lost them, so I bought a new set which seemed to be much more brittle than my original set! They seemed to break every second or third use which of course leaves me in a rather tight spot as no drill bit known to man can drill out an easy out broken off inside the hole you drilled in the broken bolt to remove it!! I have gone through several sets in several different styles in the last 5 years all due to premature failure, and when you need to get a customer up and running before the next day, this is not a good thing to happen!

So my question to all of you is: What is the most rugged and trust worthy style and brand of busted bolt removers out there?

Your help will be greatly appreciated as the well being of three beautiful children depend on it!

What I once did was to use my dremel and a cutting disc to cut a deep groove through the bolt.
Then I could use a simple flat screwdriver to take it out.

Of course this only works if you have something to work with. This would not work with a bolt that breaks off inside the hole.

How about drilling it out with a drill that is slightly bigger than the bolt itself, and then threading the hole for a bolt that is 1 size wider?

Originally Posted by Bruno

How about drilling it out with a drill that is slightly bigger than the bolt itself, and then threading the hole for a bolt that is 1 size wider?

That is definitely an option, but I am shooting for the cheapest and quickest option for my customer, until more time consuming options are the only choice I have!

The French brand Facom is very good, but expensive.
Apart from the easy-outs with a left thread, that seem often to only put more stress on the broken stud, and then break off, there's also another option. It uses a 5 pointed rod that is to be hammered into a pre-drilled hole. Then you can unscrew with a key.

If you have something to grab onto and room to work with, vise grips will do the trick. Worked on a caliper bolt after the screw extractor broke off on me.

I agree with Bruno. Buy a set of taps and drill bits and drill out busted bolts. Then just cut new threads with the taps. This actually takes less time then using bolt extractors and I find that taps are much more durable.

+1 on the taps.
Or, Drill it out and insert a Helicoil.

Jerry

I carry a large tap and die set on my truck, And they come in handy when you need them, but have found over the years that removing the broken bolt without damaging the threads is almost always the most efficient and timely way to take care of the situation! The last five years though make me think that maybe drilling and tapping, due to the lack of a good quality bolt extractor, is the way to go!
Price is not a consideration when it comes to tools that I make my living with, so even the most expensive tool will be considered!
Any other ideas?

I had decent success with a friend's Craftsman bolt extractor and the application of Kroil beforehand. Good luck if you have to deal with a broken grade 8 though. That's where the good old 'hot wrench' (oxy-acetylene torch) comes in handy.


Wayne