removing stuck headless bolt

>5/16''-24 bolt stuck in very rusty hole
>either head sheared off or I cut it, don't remember it was a long time ago
>now i finally need to remove bolt
>tried pic related
>drilled appropriate sized hole with difficulty
>apply torque, hear creaking
>eventually the back-out bit breaks off inside the hole, the bolt did not budge
I think the hole may not have been completely centered. I found it hard to drill without having the cutting bit trying to walk.

Anyway, I simply just welded over the mess and left the broken piece stuck inside. I ground it down so now I have a flat top to work with again.

I want to try cutting a slot into it and simply using a screwdriver. Would this work? How can I make a cut that is narrow enough and precise enough that it crosses the center?

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  1. 1 year ago
    Anonymous

    pic related is before i started.

  2. 1 year ago
    Anonymous

    bump

    • 1 year ago
      Anonymous

      You cant even post a pic of what it looks like right now and you are bumping?

      • 1 year ago
        Anonymous

        i don't actually live where the bolt is. i just decided to ask about it today because whatever.

        Fwiw I like the square profile extractors better than those.

        But since you've already tried an extractor I assume you've also applied penetrating oil and heat in conjunction with the extractor.

        Weld a nut on there.

        >weld a nut
        this is probably what I'll try next

  3. 1 year ago
    Anonymous

    You could drill and tap for a lefty thread. That way as you intert a bolt, it will loosen the stuck one while tightening the lefty

    • 1 year ago
      Anonymous

      No he cant, it has a broken, hardened extractor inside thats been welded over.
      Guy is a moron, he would have to use a carbide burr or something similar to get into it.

  4. 1 year ago
    Anonymous

    Fwiw I like the square profile extractors better than those.

    But since you've already tried an extractor I assume you've also applied penetrating oil and heat in conjunction with the extractor.

    Weld a nut on there.

  5. 1 year ago
    Anonymous

    Bridgeport and endmill

    • 1 year ago
      Anonymous

      either or...

      >welded over the mess
      you're here, telling me that you can weld to this bolt, and you're stumped as to how you can remove it? are you serious? build up enough of a bead that you can weld a hex head to the fricker and back it out. snaps off again, weld it again. if it's still being a c**t, weld a nice big chunk of cold roll to it and use it as a slide hammer to yank it out. if you're having this hard a time in the first place, don't worry about your tapped hole, it's already fricked for at least one reason.

  6. 1 year ago
    Anonymous

    Weld a nut on it, whittle it out with a carbide, or just blast it with the cutting torch.

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