I have had incredible success with welding a nut on a broken bolt using a
wire feed welder with the nut held in position with pliers and the wire
inserted inside the nut so the weld is captured within the nut. Then pull
the weld trigger and make a weld puddle inside the nut.

I've used this trick on broken bolts that were overhead and in impossible
positions to drill. So far.. the welding heat traveled down the broken
seized bolt and broke the rust bond on the threads allowing the bolt to be
turned out with a socket on the "new nut".

One trick that really seems to help is a quick quench with water while the
weld is still glowing hot. Seems to shrink the bolt in place and break the
bond better.

Good luck. Play safe.

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On Wed, Jun 14, 2017 at 2:46 PM, Randy Bennell via Mercedes <
mercedes@okiebenz.com> wrote:

> On 14/06/2017 4:28 PM, Floyd Thursby via Mercedes wrote:
>
>> This one sheared off basically flush, I can probably centerpunch it to
>> get a hole to start drilling if I ever need to deal with it, which will be
>> after I get it running, if I get it running.
>>
>> --FT
>>
>> Sounds like a good opportunity to weld a nut on the end and use that to
> turn it out.
> Heat from the weld will loosen the threads as well.
> More difficult to do if the bolt is broken off below the surface but
> should be fairly easy if it is flush.
>
> RB
>
>
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