How to extract a sheared bolt:
- Lincoln Flux Core Welder (Proper welding gear assumed)
- Washers (slightly larger than the bolt diameter)
- Nuts (slightly larger than the bolt diameter)
After I got the bolt built up beyond the surface, I took a washer and welded it to the bolt (inner ring of course). When that has cooled a little bit, take a nut and weld it to the bolt and washer. I started on the inside and filled the whole nut. After the nut cooled, I then laid a couple welds to bond the outer edge of the washer with the nut. This is important to maximize the surface area of the weld and strength.
Once the bolt has cooled down to a warm temperature, start trying to loosen the bolt. I would highly recommend NOT just cranking down on it. Take your time. I moved it about a quarter turn at a time, then wiggled it back and forth until it was very loose…then another quarter turn. Repeat this until your bolt is out. You may get a tired shoulder!
