How To Remove a Stubborn Stripped Bolt

Removing a stubborn stripped bolt can be a major headache. It’s easy to get frustrated while attempting to extract it, but before you launch your wrench into the neighbor’s bushes, there are proven methods to loosen a bolt—whether it’s rusted, stripped, or broken. In this article, we’ll tell you how to remove a stripped bolt, when to call a professional, and ways you can prevent bolt stripping.

What Tools Do You Need To Remove Stripped Bolts?

If you’re an avid do-it-yourselfer (DIYer), you probably have most of the tools you need to extract a stripped bolt. However, you may not have a bolt extractor set. Those cost anywhere between $13 and $25*. Having a dedicated extractor set can make the process a little easier, but you really don’t need it. Collect the following tools so you can remove the bolt in a cinch:  

• Box-end wrenches
• Center punch
• Corded or cordless drill
• Drill bits
• Hacksaw
• Hammer
• Left-handed drill bits
• Locking pliers (vice grips)
• Machine oil
• Oscillating multitool
• Penetrating oil
• Reciprocating saw
• Socket wrench set

*Cost data in this article sourced from Angi.

Prep Before Removing a Stripped Bolt

There are a few steps to take before removing the bolt once you’ve found all the tools you’ll need. Safety comes first, so make sure you: 

• Keep a first aid kit close to your workspace
• Use work gloves so sharp edges don’t catch your skin
• Ventilate the area you’re working in when using chemical products
• Wear safety glasses 

To figure out which extraction method you need to take to wiggle that bolt free, you’ll need to assess the situation. Take a moment to examine the stripped bolt to learn:

• If the bolt is load-bearing
• The extent of stripping or rust
• Whether the surrounding area is a material prone to damage.

Methods for Removing Rusted Bolts

Rust is a common bolt-stripping culprit, but luckily, there are a few ways to remove a rusted bolt. We’ll cover all three methods to extract a bolt if it’s rusted below:

Use Penetrating Oil

DIYers apply penetrating oil as a first step to loosen a rusted bolt, which includes: 

1. Apply penetrating oil to the bolt.
2. Let the oil sit according to the product instructions.
3. Try to loosen the bolt with a socket wrench.

If that doesn’t do the trick, you can apply more oil and let it sit even longer before you move on to another method.

Take the Hammer and Shock Method

If the oil doesn’t work, you can try a little shock to break the rust’s hold:

1. Apply penetrating oil to the bolt.
2. Use a hammer to tap the side of the bolt head but avoid damaging the bolt head.
3. Loosen the bolt with a wrench.

Apply Heat

When that rusted bolt is a bit too stubborn for the oil and shock methods, you can try using some heat, which includes:

1. Use a propane torch to heat the area around the bolt—but do so carefully if the components surrounding the bolt are heat-sensitive.
2. Allow the bolt to cool slightly.
3. Apply penetrating oil and attempt to remove the bolt.

Ways To Extract Stripped Bolt Heads

If you’ve noticed the bolt’s threads are worn away or the bolt head is rounded or broken off, you have a stripped bolt. Check out the ways to loosen a stripped bolt below: 

Trying the Rubber Band Trick

We didn’t mention this in the tool list above, but a simple rubber band might just do the trick. Give this method a try: 

1. Place a wide rubber band between the bolt head and your wrench.
2. Press firmly and turn the wrench to remove the bolt.

Using a Bolt Extractor Set

If you can’t get enough of a grip with the rubber band, you might need to use a bolt extractor. Whether you already have one, need to buy it, or can borrow a friend’s, follow the steps below once you have one in hand:

1. Choose an extractor slightly smaller than the bolt.
2. Tap the extractor into the bolt head.
3. Turn counterclockwise to remove the bolt.

Cutting a New Slot

Sometimes you’ll need to create a new grip point when you’re dealing with severely stripped bolts, which includes:

1. Use a hacksaw or Dremel tool to cut a slot across the bolt head.
2. Use a flathead screwdriver in the new slot to turn the bolt.

Dealing with Broken Bolts

A bolt can sometimes break off entirely, which means the shaft is stuck in place. You can handle this situation in a few ways: 

Drilling Out the Bolt

Remove the bolt’s shaft by taking these steps with a drill: 

1. Center punch the middle of the broken bolt.
2. Start with a small drill bit and gradually increase the size.
3. Drill slowly and use cutting oil to prevent overheating.

Using Left-Handed Drill Bits

Left-handed drill bits can sometimes extract the bolt as they drill:

1. Insert the left-handed bit into the drill.
2. Drill into the center of the bolt.
3. As you drill, the bit may catch and begin to back out the bolt.

Employing Screw Extractors

Screw extractors are specialized tools for removing broken bolts:

1. Drill a pilot hole in the center of the broken bolt.
2. Insert the screw extractor into the hole.
3. Turn counterclockwise to remove the bolt.

Advanced Strategies for Stubborn Stripped Bolts

When you’ve tried all the methods above and you still can’t remove that stripped bolt, you’ll need to take a more advanced technique. 

Welding a Nut to the Bolt

We recommend that only experienced DIYers take this method to remove a stripped bolt. Make sure you take all proper safety precautions as you follow the steps below:

1. Clean the surface of the stripped bolt.
2. Weld a nut onto the bolt head.
3. Use a wrench on the welded nut to remove the bolt.

Chemical Rust Removers

You can use a chemical solution to dissolve the rusted bolt by taking the steps below:

1. Apply a rust remover—but make sure you follow the manufacturer’s instructions.
2. Let the solution sit for the recommended time.
3. Try to remove the bolt with a wrench.

Professional Machining Services

You may want to contact a professional to help you remove a bolt if you’re having trouble with it or it’s a high-value application. A machine shop has specialized equipment to remove stripped bolts, and a machinist can even repair or replace damaged threads.

Key Considerations for Bolt Stripping

Now that we’ve covered the many methods you can take to remove that stubborn bolt, you may want to consider the following factors that can help you decide the right course of action:

• Damage control: You’ll want to use a method less likely to cause damage if the component surrounding the bolt is valuable or reusable.
• Environmental factors: Remember to work safely. You’ll need to adjust your expectations and method if you’re in a confined space, working in corrosive environments, or located in an area with flammable material. 
• Force versus precision: It may seem like using a hammer or saw is the right choice, but precision tools, such as a drill or extractor set, might save time and effort. Balancing force and precision can be the key to a successful removal.
• Surrounding area: You have to take the area surrounding the stuck bolt into account or you could damage the thread or ruin its components. For example, when a bolt is in aluminum or brass, you may have to apply a gentler method than if it’s in steel or iron.

Preventing Future Bolt Stripping

Removing a stubborn bolt can take time and money, but you can take some steps to prevent future bolt stripping. Maintaining your equipment and fasteners can help, so remember to clean bolts regularly and replace rusted, worn, or damaged bolts proactively.

You have less of a chance of bolt stripping when you use the right tools. To do this, take the following steps:

• Avoid using adjustable wrenches on hex bolts when possible.
• Make sure wrenches and sockets fit snugly.
• Use a torque wrench when specified and try not to over-tighten bolts.

One other trick to prevent bolt stripping is to use anti-seize compounds. You can use it on bolts that are in high-temperature or corrosive environments but use it sparingly so it doesn’t interfere with torque specifications.

Stripped Bolts: Our Conclusion

You can remove a stripped bolt by using the right tools and techniques. There are several methods to extract a bolt, which range from using a rubber band to welding and everything in between. We recommend practicing patience when trying to loosen a bolt and hiring a professional if you get too frustrated or you’re working with highly valuable or extremely stubborn equipment.