Drilling out a stubborn bolt can be quite a challenge, especially when it’s rusted or stripped. But don’t worry I am here to guide you!

How to drill out a bolt? To drill a bolt out, start by making a small dent in the middle with a punch.

Then, use a drill with a bit slightly bigger than the bolt, gradually increasing the size until the bolt comes out.

In this blog, I’ll show you 5 easiest way to drill out a bolt. I’ll also include troubleshooting tips, safety tips, and answers to commonly asked questions.

How to Drill Out A Bolt

So, when you’re faced with a bolt that won’t move around, the first thing to do is create a small dent in the center using a center punch.

This helps your drill bit stay on track. Then, start drilling with a bit slightly smaller than the bolt’s diameter, gradually increasing the size until the bolt gives up and comes out.

Tools and Stuff You’ll Need

Before we get started, gather up the things you’ll need:

1. Choosing the Right Drill Bit

• Check the bolt size using a micrometer.
• Think about what the bolt’s made of; for hard stuff like stainless steel, use a cobalt drill bit. For softer metals like aluminum, a high-speed steel bit will do.
• Get a sharp bit; you want one with a pointy end and sharp edges.

2. Stuff for drilling

• You’ll need a good power drill.
• Get some vice grips or pliers to hold onto that stubborn bolt.
• Lubricant (oil or cutting fluid) will keep things cool and help your drill bit last longer.

3. Safety Gear and Stuff

• Protect those eyes with safety glasses.
• Keep your hands safe with gloves.
• Drilling can be noisy, so plug your ears with earplugs or earmuffs.
• If there’s a lot of dust flying around, throw on a respirator.
• Just in case things get a bit too hot, keep a fire extinguisher nearby.

Getting Your Workspace Ready

Now, before you dive into drilling, make sure your workspace is all set:

1. Clean Around the Bolt

Grab a wire brush or a cloth and clean up the area around the bolt. This makes it easier to see, and no one wants debris getting into the hole you’re about to drill.

2. Hold everything in place

Use a vise or a clamp to keep your workpiece steady. You don’t want it moving around while you’re drilling; that could cause some trouble.

3. Mark the center

Time to be accurate. Use a center punch or a nail to make a little dent right in the center of the bolt. This is like a target for your drill bit, making sure it stays on track.

5 Steps to Drill Out A Bolt

Now, let’s go through the actual drilling process:

1. Pilot Hole First

To drill bolts start with a small. Create a pilot hole in the center of the bolt using a bit slightly smaller than the bolt’s diameter. Apply some pressure, but don’t go crazy.

2. Pick the right drill bit

Once you’ve got that pilot hole, choose a drill bit a bit larger than the bolt’s diameter.

Make sure your drill is set to low speed and keeps things steady. Oh, and don’t forget to keep the drill bit lubed up.

3. Drill, Drill, Drill

It’s time to get drilling. Keep the drill perpendicular to the surface, so your hole stays straight. Keep it cool with some lubricant, and you’re good to go.

4. Left-Handed Bit or Screw Extractor

If your bolt is being extra stubborn, try a left-handed drill bit or a screw extractor. These can help loosen things up and get that bolt out.

5. Cleaning Up the Mess

Once you’ve drilled out the bolt, you might have some leftovers. Use a pick or a small screwdriver to clean up any bits still hanging around.

If the bolt broke off below the surface, you might need a tap and die set to fix things up.

Troubleshooting Tips

Running into some issues? Here are a few tips to help you out:

1. If the Drill Bit Breaks

Don’t panic. Use pliers or vice grips to grab the broken end and twist it out.

If that doesn’t work, drill into the broken bit with a smaller bit and then pull it out with pliers. If all else fails, you might need an extraction tool.

2. Hard-to-Reach Bolts

Sometimes bolts hide in tricky places. Use an extension bar, a flexible drill bit extension, or a socket with a universal joint to reach them. You might need to remove other stuff to get to the bolt.

3. Keeping It Straight

Drilling straight is key. Use a center punch to mark the center, pick the right drill bit size, and drill at a slow and steady speed. This keeps things on track and prevents any wandering.

Preventative Measures

Now, let’s talk about avoiding the need to drill out bolts altogether:

1. Install and Maintain Right

Make sure you put your bolts in right in the first place. Follow torque specs, tighten them correctly, and check for wear or damage regularly.

2. Lubricate and Use Anti-Seize

Make things easy on yourself by using anti-seize compounds and lubricants. They reduce friction, making bolts easier to remove.

3. Choose the Right Materials

Think ahead. Pick materials that work well in specific situations. Stainless steel for corrosion resistance, for example.

Conclusion

Taking out a stubborn bolt can be a bit tricky, but drilling it out is often the best way. Start with the right drill bit, mark the center, and gradually drill until the bolt gives in and comes out.

As we wrap up, let’s remember the key steps: choose the right tools, drill carefully, and take your time. Rushing or using the wrong tools can lead to mistakes or damage, so be patient.

Drilling out a bolt might not be a quick and easy job, but with practice and patience, you can master it.

It’s a handy skill for all kinds of DIY or repair projects. So, keep at it, and soon you’ll be confidently tackling even the trickiest bolts.

FAQs

Can I drill through a bolt to remove it?

Yes, you can. Start by making a dent in the center with a punch, then use a drill with a bit slightly larger than the bolt, increasing the size gradually until it comes out.

How do you drill out a hardened bolt?

For a tough bolt, use a strong cobalt drill bit. Begin with a small dent in the middle, then drill slowly with increasing bit sizes until the bolt is free.

What type of drill bit do I need to drill out a bolt?

Choose a drill bit slightly larger than the bolt’s diameter. For hard bolts, like stainless steel, use a cobalt bit; for softer metals, a high-speed steel bit works.

How do you drill a bolt out of an engine block?

First, secure the area and mark the bolt’s center. Then, use a drill with the right bit, starting small and gradually increasing size until the bolt is removed.