2001 - Volume #25, Issue #1, Page #30
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How To Remove Bolts That Break Off Flush Without Doing Any Drilling
John Dyer, Kalispell, Montana: "Years ago a mechanic told me how to remove bolts that break off flush without doing any drilling. You first weld a washer that's slightly smaller than the bolt to the top of it, then weld a nut onto the washer and use a wrench to unscrew it. The heat from the welding process helps release the bolt which makes it easier to unscrew. I've used this idea many times and it really works. Sometimes I can remove the bolt even if it has broken off ębelow flush' by piling up welding material in the center of the bolt. It helps to have a small wire feed welder."
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