How to Remove Broken Studs and Screws

Removing a broken stud or screw is not difficult as long as you have the proper tools.

When the head on a bolt, screw or stud gets broken off or stripped, removing it may seem like an impossible task. Fortunately, you can resolve this issue quickly and painlessly. Certain tools and techniques have been around for many years to help extract stubborn screws and studs that don't want to budge, so with some simple preparation, you'll get those stubborn bolts out in no time.

Things You'll Need

• Screw extractor tool
• Gloves
• Welding eye protection
• Metal washer roughly the same size as the bolt
• Ball peen hammer
• Wire welder
• Nut to fit the washer
• Power drill
• Socket that fits the nut

Instructions

1. Attempt to remove the broken screw or stud with a screw extractor. This small extractor tool can be purchased for a few dollars at any hardware or automotive parts shop. It looks like a cone-shaped screw, and it works by drilling into the broken stud so you can pull out the broken metal.

2. Put on gloves and welding eye protection if the screw extractor doesn't work.

3. Place the washer over the broken screw or stud. If the stud is broken beneath the surface, beat the washer slightly into the hole with a ball peen hammer so it presses against the broken bolt.

4. Weld the washer to the broken bolt. Watch your welder to make sure you don't melt the surrounding surface as you work.

5. Weld the nut to the washer. Unscrew the bolt with a power drill and a socket that fits the nut.

Tips & Warnings

• A wire welder is smaller and easier to see than other welders, so it is highly recommended not to use a bigger welder for this task.

• Never use a welder without proper eye protection.

References

• Auto Inc.: The Art of Extraction