Anyone ever weld a nut to a stripped bolt?
 

I was removing the front rotors off the wheel on my bike this week and two of the bolts were in so tight that the allen heads stripped right out of them. This was after I tried heating them to loosen up the loctite. Now I'm stuck trying to figure out how to remove them. I could attempt to drill them out but that's always a pain and you risk damaging the threads inside the hub.

I was thinking about trying to weld a nut to the head of the bolt and then just using a wrench to loosen it after. Has anyone ever done this? My biggest concern is the weld not being strong enough to keep from shearing apart before the bolt comes loose. It's a small area and the weld would have to be in the center of the nut because if I try to weld around the outside perimeter I run a very good risk of welding the whole bolt to the rotor.

Opinions?

It there enough exposted so that if the weld fails or the bolt shears you can still get in with a drill/easy out?

I'd say it's worth trying, whats the worst that could happen?

I've done it before, and you are right. If the weld isn't strong enough then it's an exercise in futility. But both times I did it I was successful.

I don't completely understand how it's set up on the bike, but did you PB it and try heat cycling it with a torch? I would prep the spot by doing that first and then welding the nut on.

It's a bolt that goes directly into a blind hole in the hub. Panhead type that sits flush with the face of the rotor. No access to the threads. I think first I may try to dremel a groove into it and use a flathead and wrench to get it....if that doesn't work I'll weld a nut on. And if that fails I'll have to try and drill it out without trashing the threads inside the hub.

Something so simple has turned into a project.

if the allen is still sticking up, get a bolt big enough to go over it and really weld it on, then heat the area around it w/ a torch....at the same time, try turning the nut...two man job, but it should work.

ever busted a nut on a stripper? LOL sorry couldnt resist:)

How big are the bolts? can you use a set of Ez outs?

Thought about using an EZ-Out but if that happens to snap it'll be even harder to drill out then.

Yea that is a downside to them. Hardened steel FTW. But when they work, its magic.

If you can slot it maybe with some PB Blaster & heat and a impact driver it might come out. I've done that.

Break the EZ Out just get a carbide drill bit and it will break it into little bits and you can get it out with a pick. But you should be able to drill it out if the Weld idea doesnt work.

http://www.bikebling.com/v/vspfiles/...cHub-20-2T.jpg

like dat

i guess hammering in a next-size-up allen socket wont work? that coupled with an impact driver would probably do the trick. for those who dont know the impact driver of which i refer to looks like just a handle with whatever size drive on the end, you hit it with a hammer and it has a cam inside that twist and will typically break the bolt loose. good tool to have around...we use them often on the allen/torx screws on the older benz's rotors.

Yeah I tried getting the next size wrench in but it didn't work. I'll get it eventually. Too many other things on my plate at the moment.

What I had to do once (stripped head of an oil pan bolt when I had to replace the mercedes pan), is take a tap and die set, drilled/tapped inside the bolt, and used JB weld on a bolt that fit those threads. Worked like a charm, but you have to be working with a wide enough bolt on this method i think