How To Remove A Broken Bolt 6 DIFFERENT WAYS - LS Exhaust Manifold

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This is the best rusty bolt removal tutorial on the internet.

What actually works better than the turbo method is welding a 15” steel wheel from a 1985 Monte Carlo (it has to be a 1985 Monte Carlo and 15” wheel). Then , weld or anchor the wheel to one of the yellow, metal safety poles in any Walmart parking lot. Then, you’ll need some help from a buddy, but turn the engine, not the bolt, until the engine falls to the ground. Works virtually 100% of the time 25% of the time. This is not an advertisement for yellow, metal safety poles in Walmart parking lots.

If you are out in the field somewhere and don't happen to have a welder or a spare turbocharger lying around, something else that works fairly well is to always carry a small bag of torx bits with you (they are cheap and small). You can drill a hole slightly smaller than the torx bit into the broken bolt and then use a hammer to drive the torx bit into the bolt and then try to turn the bolt out using a vice grip or some other gripping tool. It works better than an extractor, and in situations where you don't have all of the "fancy" equipment you used. Depending on the size of the bolt, you can try this trick several times on the same bolt. Of course, having a torch, welder, or turbocharger always helps.

I really like the addition of the washer to the nut when welding. Heat is the key.

In most, if not all cases, you start by shocking the broken bolt. Even if it is broken inside; you take smaller, flat at the end punch, and smack it multiple times with hammer. This helps to loosen the bolt, and it will be easier to remove, no matter what method you are going to use. In addition, left-hand drill bits should be added to the list of possible solutions. Also, there are ways to make the point in the middle of the broken bolts (nobody should be just making it with a small punch). I either use the biggest drill bit that will fit the hole (make the good starting point and then continue with smaller diameter bit), or the largest transfer punch diameter that will fit the hole.

Use the vice grip with moving jaw towards the direction of rotation. This helps the torque to assist with closing the jaws.

I'm half way trough a hemi manifold... grasping for straws now. I knew steps 1-5, but #6 made my day. Stress gone. Thanks!!

Not sure what's more entertaining. You welding a turbo to an exhaust manifold or the instant I saw the turbo I went to your videos looking for DSMs. You didn't disappoint. Hahah. Thanks for the laugh today.

Bought a flux core MIG welder on Amazon for $74 after tax and shipping. It even came with a welding mask and a roll or wire. Extracted a broken stud by welding a nut on it. Worked great.

Hey guys, huge tip if you’re doing method number five, where you’re drilling a hole and screwing something out make sure you don’t spray lubricant in it and if you do then spray it out with degreaser or isopropyl alcohol after so you get Maxximum grip and there is no slipping Make sure you do this before you hammer in that removal screw! Thank me later

Lots of useful info there. Thanks for posting. I loved the turbo-blown extractor. Just one thing: I was taught to lube taps and dies when cutting threads.

OMG this is priceless, I laughed my ass of when I heared your cutting disc sound effect🤣🤣🤣

Awesome stuff man! And thank you! Never heard of the washer method. I just put a fire to it till the gaskets start smoking

Excellent. The bane of my efforts to service my own vehicles. Getting rusted bolts off. It was your attitude towards it that made me realize it's doesn't have to be painful. But can be looked at as fun and challenging. Thanks.

Dude really welded the turbo lol 😂 Good job! Loved it! Both educational and entertaining

This would be a better experiment if you use actual broken bolts. And I always use reverse drill bits for bolt extraction. A lot of time the heat from the drilling will help free it up, and it just comes out while I'm drilling.

Very informative. It shows how difficult it is when you break off the stud flush. Thanks for sharing your skills. Good tips 👍

Thanks for the GREAT Information! Well done. If I was just startin' out wrenching, I never would have seen any of these methods. If I grew up on a farm and had a fix-it-all Dad or older brother who cared enough about me to help me learn how to fix broken equipment, maybe they might have know how to use these good ideas that you took hours to video and edit. Thank you!

This guy is hero! Thank you!