One of the biggest frustrations when you are working on a project is finding a rusted bolt that will not budge. However, follow these guide and you can get this stubborn object removed by using a few simple steps.
1. Determine if the bolt is really rusted. Some factories use thread locker, and if that is the case, you can use heat to soften it up.
2. If you are in fact stuck rusted bolt, use a wire brush to get rid of as much rust as possible from the entire bolt.
3. Using the right tool will make the job easier. Open-end wrenches may slip and round off the flat sides of a nut, so try a 6-point box end wrench instead.
4. Make sure you are trying to turn it the right direction. It's easy to get turned around if you are in an awkward position.
5. Use penetrating oil or some type of liquid thread loosener. You can try a mixture of 1/2 Acetone and 1/2 ATF, but work in a ventilated area because of the fumes. Soak the threads with plenty of the penetrating oil. You may need to keep adding oil, and soak it for hours for it to be effective
6. The phosphoric acid in a diet cola is effective in removing rust. Pour it on the bolt, and wipe off the rust with wadded up aluminum foil.
7. Pour ordinary hydrogen peroxide onto a rusty bolt, and leave it for a while. Apply a stiff brush to the rust, and you should be able to get the bolt to move.
8. Use a wire brush to remove the loose rust, and pour vinegar on the stuck bolt. Dip an old toothbrush into vinegar, then into baking soda, and clean the remaining rust off.
9. Use a ratchet with a long handle or a breaker bar for more leverage. Use smooth, continuous pressure, and stop if the tension feels soft suddenly, because that may indicate that the threads are stripping, or the bolt is breaking.
10. When a nut is bonded to a bolt, you can heat one side of the nut, which causes it to expand enough to break the bond or melt the locking compound. Before using a flame, thoroughly clean off any penetrating oil, and be sure the flame does not get too near any plastic or anything else flammable. Since you will be concentrating on your task, ask someone else to watch for signs of flames or smoke. If you must work close to something that heat may damage, you can use fireproof welder's blankets to shield it.
11. NPT pipe plugs can be removed from cast iron by heating the iron and dripping candle wax on the threads. The paraffin from the candle will lubricate the threads and help you to remove the plugs. Use a socket that fits tight for this procedure.
12. If all else fails, try an electric or pneumatic impact gun using the correct impact socket, safety glasses and gloves. If you can, use a wrench to hold the bolt as you apply the impact to the nut side.
