How to Remove a Rounded Bolt

A rounded bolt refers to a bolt whose head has worn or been deformed due to prolonged use, excessive torque, or corrosion, losing its normal gripping surface and making it difficult to remove with conventional tools. When you encounter a rounded bolt that is damaged or cannot be removed, there’s no need to panic.

In this article, we will introduce 12 effective methods on how to remove a rounded bolt. Let’s begin this removing journey!

Part 1. Challenges of Removing Rounded Bolts

In many mechanical devices, bolts are essential tools for securing connecting parts. However, over time, bolts can experience wear, corrosion, or excessive tightening, causing the bolt head to become rounded and making it impossible to tighten or remove using regular screwdrivers or wrenches.

At this point, a rounded bolt becomes a problem, especially during emergency repairs or part replacements, where it can often leave one at a loss on how to proceed.

Don’t worry, we will introduce different ways to move a bolt that is rounded off in the following parts.

Part 2. Use Tools to Remove a Rounded Bolt

Way 1: Use a Screw Extractor

A screw extractor is a specialized tool for removing damaged bolts. It can effectively help you remove immovable rounded bolts. If you need to remove a rounded bolt in a tight space, this method is the way to go.

Screw extractors are typically made of hardened materials and need to be fixed on the bolt head and rotated clockwise or counterclockwise. Make sure to choose the right size of screw extractor to ensure a firm grip on the bolt and apply enough torque.

Way 2: Use Power Tools

If manual operation is difficult, you can use power tools like an electric drill or power wrench. Select an appropriate drill bit or socket and adjust the speed accordingly.

The powerful torque of power tools can help loosen tightly fastened bolts. Be careful when using power tools to control the force and avoid slipping or damaging surrounding parts.

Part 3. Heating and Cooling Methods to Remove a Rounded Bolt

Way 3: Use Flame Heating

If the bolt is rusted and stuck, you can use a torch to heat it. The high temperature will loosen the connection between the bolt and the surrounding materials, making it easier to remove.

When using flame heating, make sure to heat evenly and avoid overheating, which could damage nearby materials. After heating, try loosening the bolt with a wrench or screwdriver.

Way 4: Use Frost Cooling

In contrast to heating, cooling can also effectively loosen bolts. Using dry ice or freeze spray to rapidly cool the bolt creates a temperature difference that can help loosen the bolt.

Ensure that no surrounding parts are sensitive to the cold, and allow enough time for the cooling to take effect.

Part 4. Use Physical Force to Uninstall a Rounded Head Bolt

Way 5: Use a Hammer to Tap

If the bolt is particularly tight, you can tap the tool or bolt head with a hammer. Light tapping creates an impact force that can help loosen the bolt. Be careful when using the hammer, as excessive force may damage surrounding materials or tools.

Way 6: Increase Torque

If manual tools cannot loosen the bolt, you can use a torque wrench to apply greater force. By adjusting the torque wrench settings, you can effectively increase the force applied to the bolt.

Choose an appropriate torque value to ensure adequate loosening force, but avoid over-torquing to prevent damage to the bolt or surrounding parts.

Part 6. Alter the Contact Surface to Remove a Rounded Bolt

Way 7: Use Sandpaper to Increase Friction

Using sandpaper on the bolt head can increase friction between the tool and the rounded bolt surface, helping the tool to grip the bolt more firmly.

You can lightly sand the surface of the bolt with coarse sandpaper to make it rougher, thus increasing grip. This method is effective when the bolt is not completely damaged.

Way 8: Use Anti-Slip Tape

Wrap anti-slip tape around the bolt head to provide additional friction and help the tool grip the bolt surface better. Anti-slip tape can work effectively when the tool’s contact surface is too smooth.

Part 7. Try Chemical Methods to Remove a Rounded off Bolt

Way 9: Use Penetrating Oil

Penetrating oil can effectively seep into the bolt and base, helping to loosen rusted bolts. Choose a high-quality penetrating oil and spray it evenly on the bolt. Wait for 15 to 30 minutes to allow the oil to take effect. Penetrating oil generally helps lubricate the bolt, reducing the effects of rust.

Way 10: Use Bolt Dissolving Agent

A bolt dissolving agent is a chemical liquid specifically used to dissolve rusted bolts. It can break down the rust and corrosion around the bolt, making it easier to remove. When using this agent, follow product instructions and avoid contact with unintended surfaces to ensure safety during the process.

Part 8. Use Destructive Methods to Remove a Rounded Bolt(Only to Be Used as a Last Resort)

Way 11: Drill a Hole in the Bolt

If the bolt is damaged and cannot be removed by conventional means, you may consider drilling a hole in the center of the bolt to gradually weaken its structure. Choose a drill bit that matches the diameter of the bolt, and be careful to avoid damaging the external threads of the bolt.

Way 12: Cut the Bolt Off

If the previous methods don’t work, you can use an angle grinder or cutting tool to cut off the bolt head. Cutting through the bolt will separate it from the base.

This method is effective but will cause damage to both the bolt and the surrounding structure, so it must be done with caution, and appropriate protective equipment should be worn.

Part 9. How to Prevent a Rounded Bolt?

The best way to prevent rounded bolts is to regularly inspect the condition of the bolts and take appropriate measures to avoid damage:

• When installing or removing bolts, ensure that the proper tools and torque are used. Avoid over-tightening or loosening bolts excessively.
• Regularly check the condition of the bolts, especially in harsh environments, and replace aging or damaged bolts in a timely manner.
• Use anti-corrosion coatings or rust treatments to reduce the likelihood of bolts being damaged by rust.

Final Thoughts

When facing immovable rounded bolts, you can try the 12 methods outlined above to find effective solutions. If you find that your bolt problem cannot be solved with the methods described above, it may be time to seek professional help.

Regular maintenance and care, such as checking bolts periodically and applying lubricants, can effectively prevent bolt damage and extend the lifespan of equipment. Hope you can successfully deal with rounded bolts and regain your work efficiency.

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