How To Remove A Stripped Bolt

Dealing with a stripped bolt can be one of the most frustrating experiences for cyclists, mechanics, and DIY enthusiasts. Whether you’re working on your bike, car, or home project, a stripped bolt can halt your progress and cause unnecessary stress. Fortunately, there are several effective methods to remove these stubborn fasteners without damaging your equipment. This guide will walk you through proven techniques to successfully extract stripped, rounded, or stuck bolts, saving you time, money, and frustration.

What You’ll Need

Depending on the method you choose, you may need some of the following tools and materials:

– Penetrating oil (like WD-40, Liquid Wrench, or PB Blaster)
– Pliers (vice grips, locking pliers, or channel locks)
– Rubber band or steel wool
– Hammer and punch
– Screw extractor set
– Dremel tool or rotary tool with cutting disc
– Flat-head screwdriver
– Hacksaw or metal file
– Drill and drill bits
– Heat source (heat gun or torch)
– Safety glasses and gloves

Understanding Stripped Bolts

Before attempting removal, it’s important to understand what causes bolts to become stripped. A bolt becomes “stripped” when the edges of its head or threads become rounded, making it difficult for tools to grip. This typically happens when:

– Using the wrong size tool
– Applying excessive force
– Working with worn or damaged tools
– Dealing with rusted or corroded fasteners
– Using low-quality bolts

Preparation Steps

1. Clean the Area

Remove any dirt, grease, or debris around the bolt. This gives you better access and visibility.

2. Apply Penetrating Oil

Apply a generous amount of penetrating oil to the bolt and surrounding area. Let it sit for at least 15-30 minutes (or overnight for extremely stubborn bolts) to break down rust and corrosion.

3. Remove Excess Oil

Before attempting removal, wipe away excess oil from the bolt head using alcohol and a clean rag. This prevents your tools from slipping further.

Method 1: Using Rubber Band or Steel Wool

For slightly stripped bolts, this simple trick often works:

1. Place a wide rubber band or piece of steel wool over the bolt head
2. Press your wrench or screwdriver firmly into the rubber band/steel wool and onto the bolt
3. Turn slowly and with steady pressure
4. The rubber or steel wool helps fill the gaps and provides additional grip

Method 2: Pliers Method

1. Get a good pair of locking pliers or vice grips
2. Adjust the pliers to tightly grip the head of the bolt
3. Lock the pliers onto the bolt head
4. Turn counterclockwise with steady pressure
5. If the bolt doesn’t budge, try tightening the pliers further

Method 3: Creating a New Slot

This method is particularly effective for rounded bolt heads in tight spaces, such as cleat bolts on cycling shoes:

1. Cut a New Slot

1. Using a Dremel tool or hacksaw, cut a straight slot across the top of the bolt head
2. Make the slot deep enough for a flat-head screwdriver to grip properly
3. Clean away any metal shavings

2. Use a Screwdriver

1. Select a large, flat-head screwdriver that fits snugly in your new slot
2. Apply downward pressure while turning counterclockwise
3. If necessary, tap the screwdriver with a hammer to help it seat better

Method 4: Screw Extractor

For severely stripped bolts, a screw extractor kit is often the best solution:

1. Select an appropriate size extractor for your bolt
2. If necessary, drill a small pilot hole in the center of the bolt
3. Insert the extractor into the hole (they typically have reverse threads)
4. Turn the extractor counterclockwise with a wrench
5. The extractor should bite into the bolt and begin to back it out

Method 5: Heat and Impact

Sometimes, heat can break the bond of seized bolts:

1. Apply heat to the area around the bolt using a heat gun or torch
2. Be careful not to overheat or damage surrounding components
3. After heating, try removing with an appropriate tool
4. Alternatively, use an impact driver which delivers sharp, rotational blows

Method 6: Welding Method

For those with access to welding equipment, this advanced technique can be very effective:

1. Weld a nut onto the stripped bolt head
2. Allow the weld to cool completely
3. Use a wrench on the welded nut to remove the bolt
4. The heat from welding often helps break the corrosion bond as well

Dealing with Specific Situations

Cleat Bolts on Cycling Shoes

Cycling cleats often have small bolts that can easily become stripped:

1. Try the rubber band method first
2. If unsuccessful, the slot-cutting method works particularly well
3. Apply penetrating oil and let it sit overnight
4. Consider using a small screw extractor designed for precision work

Bolts in Tight Spaces

1. Use right-angle tools when possible
2. Consider the slot-cutting method with a narrow blade
3. Use needle-nose locking pliers if there’s minimal clearance
4. As a last resort, you may need to create additional access by removing surrounding components

Prevention Tips

To avoid dealing with stripped bolts in the future:

1. Use the correct size and type of tool
2. Apply torque gradually, not suddenly
3. Keep tools clean and in good condition
4. Use anti-seize compound on bolts in areas prone to corrosion
5. Replace low-quality bolts with higher-grade ones
6. Clean and lubricate threaded areas regularly

Frequently Asked Questions

Can I use super glue to remove a stripped bolt?

While some suggest gluing an Allen key or tool to the bolt, this method is rarely effective and can make the situation worse. The glue typically isn’t strong enough to withstand the torque needed to remove a stuck bolt.

Will WD-40 work as well as specialized penetrating oils?

WD-40 provides some penetrating properties but specialized penetrating oils like PB Blaster or Liquid Wrench are typically more effective for freeing severely rusted or seized bolts. For best results, apply the penetrating oil and let it work overnight.

What if I’ve tried everything and the bolt still won’t budge?

If all methods fail, you may need to drill out the bolt completely. This should be considered a last resort as it requires precision to avoid damaging the threads. In some cases, consulting a professional mechanic may be the wisest choice.

How do I remove a bolt if the head breaks off?

If the bolt head breaks off, you’ll need to extract the remaining threaded portion. Try using a screw extractor or, if the bolt is exposed enough, grip it with locking pliers. In some cases, you may need to drill out the remaining bolt and re-tap the threads.

Are there any risks to using heat to remove bolts?

Yes. Excessive heat can damage surrounding components, especially plastic parts, electronic components, or parts with lubricants. Always be cautious with heat, use heat shields when possible, and avoid heating components like bearings or seals that could be damaged.