Yahoo Autos A Step-by-Step Guide on Removing a Seized Bolt
If you happen to find yourself struggling with a seized or broken bolt lodged in a piece of metal, don't worry, Hagerty put together a sweet video DIY guide using fairly simple tools to help you out.
If the bolt you're dealing with happens to be sticking out of the metal thread, that's good news. It means there's still something to grab onto once it comes time to remove it. In order to get it un-seized, host Davin Reckow uses a torch to heat up the threaded area around the bolt to expand the metal. This loosens everything up and allows him to start twisting the bolt out of its location using a pair of vicegrips.
Reckow warns that when working with aluminum, you should be cautious about overheating. Unlike steel, aluminum doesn't glow red when it gets hot, which makes it easy to mistakenly overheat the piece you're working on and potentially damage it.
If the bolt you're dealing with happens to have broken flush with the metal (as many are), things get slightly more complicated. Reckow uses a MIG welder to weld a nut onto the broken bolt, meshing them into one piece of metal. This allows him to use the nut as a grab point to twist out the fused bolt.
Reckow notes it's also good to have a steel brush handy to remove any surface rust or other gunk from the area you're about to heat up. Of course, a pair of safety glasses and heat-resistent gloves should be used. And if you're welding, have a good welding helmet handy.
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