Frozen/stuck Bolt in Aluminum. Plasma cutter?

forceten

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Not tractor related but I'm sure somebody has some advice for me here :D

One of our bigger tanker trucks Tank tie downs snapped. Not uncommon. I have changed probably 10-12 over the years.

Except this was on one of our older trucks. Meaning the bolt has been in there for 15 years. Went to go take out one side and no go - same with the other. Was able to grind off the head and get the shafts off. But I still have the bolt into the aluminum stuck. Oxidezed/welded together for better terms. No threads - the bolt just goes through a hole in the aluminum block. No amount of hammering or impact wrenching is making it budge.

I need them out to get a new tie down in place. Already tried heating them up - with kroil. No go. Tried some wax - no go. Unless I need to heat them up longer and use more kroil and wax?

Pictures of the offending bolts (terrible spot one side is in) and then another tie down thats in tact so you guys get a picture of the problem.

I can grind them flush and try to drill them out. But they are grade 8 on one side and grade 5 on the other. I know its gonna be a bitch to drill.

We have a plasma cutter - I was thinking grind them flush and them hit it with the plasma and burn it right out? Gonna splatter a bit but should be able to blow it out? I have cut metal before with it but never tried to blow out a gridned bolt before. Little leary of using the plasma cutter on the vehicle. I can get a good ground, but lots of electronics on the engine and ecm computer I would worry about if the plasma doesnt ground good and travels to find the expensive electronics.


Any advice? I know lots of people here have older tractors and must have had tons of stuck bolts before. I can almost always get a metal bolt out of metal. But moetal bolt stuck on aluminum is got me stumped.
 

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coachgeo

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how about drilling them out. A royal PITA though. Could try an Easy out to help attempt to turn the remaining bolt while heating/Krollling/Waxing
 

coachgeo

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Boiling water and an air hammer.
ahhhh. Temp brings up an idea.

chill/Freeze the stud (CO2 source like Computer Keyboard spray cleaner) to contract it..

maybe heating aluminium surrounds to expand it the hole.

doing this might help break the corrosion bond between the Aluminum/steel
 

Tooljunkie

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Boiling water equals rapid expansion and rattling with air hammer in the presence of water hydraulically breaks the bond created by corrosion. The dissimilar metals will create a pretty nasty tight fit. I suggest a barrier coating of some kind when installing new bolts.
 

Daren Todd

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I run into that issue at work occasionally with aluminum plates and steel bolts. Over time they bond to each other. I usually use a combination of heating the aluminum and cooling the steel bolts. Then a BFH and a punch to drive out the snapped bolts..

After the bolts are removed, i use a round file and clean the gunk out of the holes.

When reinstalling, some copper antiseize is your best friend to help cut down on the bonding.
 

RCW

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I was thinking heat on the aluminum and air hammer also.

Daren - how to you cool the steel bolt part?

Forceten - Best wishes, hope it works out!:)
 

Daren Todd

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I was thinking heat on the aluminum and air hammer also.

Daren - how to you cool the steel bolt part?

Forceten - Best wishes, hope it works out!:)
I usually just grab a bottle of water and poke a hole on the cap. The aluminum seems to hold onto the heat more then the steel. I usually heat and cool several times. Then heat the aluminum up and start flogging on it with my 4 pounder and a punch :D
 

Diydave

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Burn out the center of the bolts with the PC. THe heat should make the bolt's bond to the aluminum break...:D:D
 

North Idaho Wolfman

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I've blow out quite a few bolts with a PC.
It sound like you would just melt the aluminum, but that's not the case, as the same corrosion that has the bolt stuck in the hole will also serve as an insulator as it is a really bad conductor of heat from the bolt to the aluminum! ;)
 

forceten

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I've blow out quite a few bolts with a PC.
It sound like you would just melt the aluminum, but that's not the case, as the same corrosion that has the bolt stuck in the hole will also serve as an insulator as it is a really bad conductor of heat from the bolt to the aluminum! ;)
Soon as I get a none rainy day I think this is what I'm gonna try. Grind it flush and then hit it with the pc and see how fast it will blow out
 

Tooljunkie

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From the diameter of the bolts, you should have lots of room to get a hole started. Or drill a pilot for dross to blow out.
 

Dwarner

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I would put some acetone/ATF on it and use a ball joint press on it. Hammering it might flare it and make it tighter.
 

DaTow'd

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I don't think copper anti seize is the right stuff to use on aluminum.
drill with a left hand drill bit maybe it will unscrew as you drill
good luck
Hank
 

North Idaho Wolfman

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I don't think copper anti seize is the right stuff to use on aluminum.
drill with a left hand drill bit maybe it will unscrew as you drill
good luck
Hank
Why not just drill it from the other side?
 

North Idaho Wolfman

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Cause grade 8 bolts a pain to drill
My comment was to why use a left had drill bit when you can get to the other side and use a right had drill bit. ;)

I agree drilling Grade 8 bolts is a major pain! :(