Weld a nut to a broken bolt
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  1. #1
    Join Date
    Feb 2007
    Location
    West By Golly Shelby NY
    Posts
    7,265

    Weld a nut to a broken bolt

    My son says Its my answer to everything.

    2000 Cheby 5.3 V8 Aluminum heads. Last manifold broken off below the surface of the head.

    I used Alstate 275 at 71 amps I built a little tit on it, then another one,..... Till I could put a 3/8" nut on it. I welded the tit to the nut and took it out after it cooled. The one next to it only had the head broken off, so I took that one out too.

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    Through this hole.
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    My lucky day. I made good $ on it too.

    David
    Real world weldin.

    When I grow up I want to be a tig weldor.

  2. #2
    Join Date
    Feb 2007
    Location
    Moncton Nb Canada
    Posts
    134

    Re: Weld a nut to a broken bolt

    That there is pretty much the only reason my truck doesn't have headers.
    Here learning to turn down the Suck...


  3. #3
    Join Date
    Jun 2008
    Location
    Extreme Southern Louisiana
    Posts
    109

    Re: Weld a nut to a broken bolt

    Quote Originally Posted by Atomik777 View Post
    That there is pretty much the only reason my truck doesn't have headers.
    My '03 has STOCK exhaust and it also has a broken bolt. I am not going to mess with it til the gasket starts leaking (been 20k miles since I noticed it).



    David, if that truck has plastic inner fenders like mine the are fairly easy to remove.
    Last edited by busyman; 06-12-2009 at 07:31 PM.

  4. #4
    Join Date
    May 2009
    Location
    NY
    Posts
    415

    Re: Weld a nut to a broken bolt

    Glad you made some money on it. It used to be I wouldn't let a customer hang around while I did that repair. I used to sell the value, not the time. Good Job. My Kinda Job
    Lincoln Ranger 8 Lincoln 175 Drill press
    Lincoln 225 mig
    Plasma
    8 ft brake
    52" jump shear

  5. #5
    Join Date
    Aug 2008
    Location
    Dansville NY
    Posts
    5,157

    Re: Weld a nut to a broken bolt

    I have certainly done my share of those of heavy construction & farm equipment as well as cars & trucks! Some go easy and others!!!!!!
    Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.& 2 Hypertherm HPR260's Plasma Cutter

    Sorry I had a bad stroke but now I am back.

  6. #6
    Join Date
    Feb 2007
    Location
    West By Golly Shelby NY
    Posts
    7,265

    Re: Weld a nut to a broken bolt

    The manifold was stock. The truck sits a lot. I gave him the price before the job. A regular auto shop would have taken off the head and probably exchanged it for a rebuilt.

    I would not do a job like that in front of a customer.... Ever...

    And sure there are days the floor is covered with nuts from failed attempts.

    David
    Last edited by David R; 06-12-2009 at 08:58 PM.
    Real world weldin.

    When I grow up I want to be a tig weldor.

  7. #7
    Join Date
    Dec 2007
    Location
    Central West Virginia
    Posts
    203

    Re: Weld a nut to a broken bolt

    LOL yep some do some don't.. When I used stick rod for that I used tiny stainless rod.

    My most recent bolt in aluminum, weld a nut on it deal, was for a neighbor in one of those pesky lawn mower deck hubs. I didn't think the hub was worth removing the 2 broken bolts.

    Anyway welded on 2 nuts, Let it cool a bit then applied a bit of heat to the Ally hub. Got them to move slightly & gave it back to him. told him to soak them with penitrant & work them out slowly. also told him if you twist one off now, go buty a new hub. No Charge.....
    IF IT WORKS, DON'T FIX IT

    Linde-VI 253,400 & 450 w/MIG35 feeders
    CNC Table with Oxweld O/A & Hypertherm 1250G3
    Lincoln Ranger GXT 250
    Hobart-MicroWire 300
    ESAB Heliarc 161
    ESAB-Mobilemaster 2 CC/CV Feeders
    & more

  8. #8
    Join Date
    Jan 2009
    Location
    Ohio
    Posts
    582

    Re: Weld a nut to a broken bolt

    ive put a washer over a broken bolt and plug welded the washer to the bolt then welded a nut to the washer. that works very well too.

  9. #9
    Join Date
    Feb 2007
    Location
    Moncton Nb Canada
    Posts
    134

    Re: Weld a nut to a broken bolt

    Quote Originally Posted by David R View Post
    The manifold was stock. The truck sits a lot. I gave him the price before the job. A regular auto shop would have taken off the head and probably exchanged it for a rebuilt.

    I would not do a job like that in front of a customer.... Ever...

    And sure there are days the floor is covered with nuts from failed attempts.

    David
    Sorry, i'll clarify...Its because i figuire, with my luck, i'd snap ALL the bolts just trying to get the old maniforlds off...Long before i even got close to the headers .
    Here learning to turn down the Suck...


  10. #10
    Join Date
    Feb 2007
    Location
    West By Golly Shelby NY
    Posts
    7,265

    Re: Weld a nut to a broken bolt

    Quote Originally Posted by El_Lloydeo View Post
    ive put a washer over a broken bolt and plug welded the washer to the bolt then welded a nut to the washer. that works very well too.
    Never tried that one, but I can see how it would be possible.

    Thanks for the tip.

    David
    Real world weldin.

    When I grow up I want to be a tig weldor.

  11. #11
    Join Date
    Jan 2009
    Location
    Ohio
    Posts
    582

    Re: Weld a nut to a broken bolt

    it just allows for more weld to be put around the nut. ive also taken oversized nuts and plug welded them to the broken bolt. let it cool good though before you get to crankin on it!

  12. #12
    Join Date
    Dec 2007
    Location
    Central West Virginia
    Posts
    203

    Re: Weld a nut to a broken bolt

    Quote Originally Posted by El_Lloydeo View Post
    it just allows for more weld to be put around the nut. ive also taken oversized nuts and plug welded them to the broken bolt. let it cool good though before you get to crankin on it!
    If there is any stud or bolt extending out from the surface I always use a nut that will fit over the stud/bolt. Makes it easier to pour it on for best penitration.
    IF IT WORKS, DON'T FIX IT

    Linde-VI 253,400 & 450 w/MIG35 feeders
    CNC Table with Oxweld O/A & Hypertherm 1250G3
    Lincoln Ranger GXT 250
    Hobart-MicroWire 300
    ESAB Heliarc 161
    ESAB-Mobilemaster 2 CC/CV Feeders
    & more

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