Removing rusty, stuck bolts. A lazy Sunday afternoon tech

[Tx Firefighter]

This is a basic tech procedure. I'm sure it's total review to most of you fellas, but hopefully it can help someone who doesn't know how to do this.

I had 4 bolts holding my cab hump on that were completely rusted and rounded off way beyond removal via wrench or socket.

First, you need to get in a patient mood...


Here is one of the perpetrators...


Take your grinder or even a file and smooth the rust off of the top of the bolt. You need nice, clean metal to work with...


Drop a nice clean nut onto the bolt nub. I buy mine at Tractor Supply for pennies...


Take your welder and weld the center of the nut up solid, nice and hot. Do not breath the fumes. The zinc plating on the nut will make toxic fumes and you will become quite sick. Just keep your head out of the way of the smoke. Nothing to get too wrapped up over...

Put a socket on the nut and twist the bolt out, easy as pie. The heat from the welding also serves to significantly loosen the rust buildup on the threads too...


Repeat as needed.

My next tech article will be how to buy a real camera that takes non blurry pictures.