Using Welder to Remove Stubborn Bolts
My customer was replacing the front wheel bearings on his Suburban. The bolts that retained the flange for the wheel bearing to the knuckle were frozen. His helper rounded the head of three of the bolts. I cleaned up the top of the bolts with a Carbide burr using Foredom flex shaft grinder and some Acetone. MIG wouldn’t work because the hole in the hub was too small for the MIG nozzle. I could have stick welded it but I wanted to camp out on top of the head of the bolt to really heat it up, so I used TIG instead. I used a conventional TIG nozzle to fit through the small access hole in the hub to gain access to the top of the bolts. One bolt was so badly rounded that I had to weld a nut on the top.
1. Rounded off head of bolt
2. Rounded off head of bolt close-up
3. Nut welded to top of bolt
4. Using breaker bar to remove bolt
5. Bolt removed