How to Remove Rusted Allen Bolts

PDF download Download Article
PDF download Download Article

Hex keys and bolts, often referred to by the trade names Allen in the United States and Inbus in Europe, are a very common fastening system. Used in everything from self-assembled particle board furniture to car parts, hex bolts enjoy widespread usage due to their resistance to stripping. However, the bolts can be very tricky to remove when they have rusted through. Learning how to remove rusted Allen bolts is a matter of assembling a few tools and exercising a lot of patience.

Steps

PDF download Download Article
  1. {"smallUrl":"https:\/\/www.wikihow.com\/images\/thumb\/9\/9d\/Remove-Rusted-Allen-Bolts-Step-1.jpg\/v4-460px-Remove-Rusted-Allen-Bolts-Step-1.jpg","bigUrl":"\/images\/thumb\/9\/9d\/Remove-Rusted-Allen-Bolts-Step-1.jpg\/aid1389005-v4-728px-Remove-Rusted-Allen-Bolts-Step-1.jpg","smallWidth":460,"smallHeight":306,"bigWidth":728,"bigHeight":485,"licensing":"<div class=\"mw-parser-output\"><p>License: <a target=\"_blank\" rel=\"nofollow noreferrer noopener\" class=\"external text\" href=\"https:\/\/en.wikipedia.org\/wiki\/Fair_use\">Fair Use<\/a> (screenshot)<br>\n<\/p><\/div>"}
    Before attempting to loosen the bolt, remove as much rust as possible. The less rust there is on the bolt, the less likely you are to snap off or strip the head when loosening it. Use a brush with stiff wire bristles to scrub rust from the threads and head of the bolt, the nut, and the surrounding metal.
  2. {"smallUrl":"https:\/\/www.wikihow.com\/images\/thumb\/0\/05\/Remove-Rusted-Allen-Bolts-Step-2.jpg\/v4-460px-Remove-Rusted-Allen-Bolts-Step-2.jpg","bigUrl":"\/images\/thumb\/0\/05\/Remove-Rusted-Allen-Bolts-Step-2.jpg\/aid1389005-v4-728px-Remove-Rusted-Allen-Bolts-Step-2.jpg","smallWidth":460,"smallHeight":306,"bigWidth":728,"bigHeight":485,"licensing":"<div class=\"mw-parser-output\"><p>License: <a target=\"_blank\" rel=\"nofollow noreferrer noopener\" class=\"external text\" href=\"https:\/\/en.wikipedia.org\/wiki\/Fair_use\">Fair Use<\/a> (screenshot)<br>\n<\/p><\/div>"}
    Penetrating oil is one of the best tools available for loosening rusty bolts, though its proper application requires patience. Apply the oil to as much of the bolt as you can access, and then let it sit for a long time. If you have several days to spare, apply the oil a few times daily for a few days. At the very least, try to give the oil a few hours to penetrate the rust. If you don't have penetrating oil, apply another type of lubricant.
    Advertisement
  3. {"smallUrl":"https:\/\/www.wikihow.com\/images\/thumb\/3\/35\/Remove-Rusted-Allen-Bolts-Step-3.jpg\/v4-460px-Remove-Rusted-Allen-Bolts-Step-3.jpg","bigUrl":"\/images\/thumb\/3\/35\/Remove-Rusted-Allen-Bolts-Step-3.jpg\/aid1389005-v4-728px-Remove-Rusted-Allen-Bolts-Step-3.jpg","smallWidth":460,"smallHeight":306,"bigWidth":728,"bigHeight":485,"licensing":"<div class=\"mw-parser-output\"><p>License: <a target=\"_blank\" rel=\"nofollow noreferrer noopener\" class=\"external text\" href=\"https:\/\/en.wikipedia.org\/wiki\/Fair_use\">Fair Use<\/a> (screenshot)<br>\n<\/p><\/div>"}
    After brushing and lubricating the bolt, use a hex key to try to loosen it. It may help to turn the bolt in both directions to begin with. Using a ratchet-style hex key with a larger handle will also improve your chances of loosening the bolt. If the head of the bolt is large enough, you can try loosening it by twisting the entire head with a wrench.
  4. {"smallUrl":"https:\/\/www.wikihow.com\/images\/thumb\/a\/a0\/Remove-Rusted-Allen-Bolts-Step-4.jpg\/v4-460px-Remove-Rusted-Allen-Bolts-Step-4.jpg","bigUrl":"\/images\/thumb\/a\/a0\/Remove-Rusted-Allen-Bolts-Step-4.jpg\/aid1389005-v4-728px-Remove-Rusted-Allen-Bolts-Step-4.jpg","smallWidth":460,"smallHeight":306,"bigWidth":728,"bigHeight":485,"licensing":"<div class=\"mw-parser-output\"><p>License: <a target=\"_blank\" rel=\"nofollow noreferrer noopener\" class=\"external text\" href=\"https:\/\/en.wikipedia.org\/wiki\/Fair_use\">Fair Use<\/a> (screenshot)<br>\n<\/p><\/div>"}
    If the hex bolt cannot be loosened using the above techniques, you can try applying heat. Heating the nut and the surrounding material can cause it to expand slightly, giving the bolt a little more room to turn. Apply heat using a hand held propane torch, being careful to heat the bolt itself as little as possible. If you are working near plastic or other materials that will melt or burn, be careful to watch for smoke.
  5. {"smallUrl":"https:\/\/www.wikihow.com\/images\/thumb\/f\/fb\/Remove-Rusted-Allen-Bolts-Step-5.jpg\/v4-460px-Remove-Rusted-Allen-Bolts-Step-5.jpg","bigUrl":"\/images\/thumb\/f\/fb\/Remove-Rusted-Allen-Bolts-Step-5.jpg\/aid1389005-v4-728px-Remove-Rusted-Allen-Bolts-Step-5.jpg","smallWidth":460,"smallHeight":306,"bigWidth":728,"bigHeight":485,"licensing":"<div class=\"mw-parser-output\"><p>License: <a target=\"_blank\" rel=\"nofollow noreferrer noopener\" class=\"external text\" href=\"https:\/\/en.wikipedia.org\/wiki\/Fair_use\">Fair Use<\/a> (screenshot)<br>\n<\/p><\/div>"}
    If none of the above methods work for removing the bolt, you can break the bolt off. This is best done with an impact gun, but can be done by hitting the bolt with a hammer or sledgehammer. After breaking the bolt off, you may have to drill the remaining piece out.
    6. Advertisement

Expert Q&A

Ask a Question
200 characters left
Include your email address to get a message when this question is answered.
Submit
      Advertisement

      Video

      Tips

      Submit a Tip
      All tip submissions are carefully reviewed before being published
      Submit
      Thanks for submitting a tip for review!
      Advertisement

      Things You'll Need

      • Stiff wire brush
      • Penetrating oil
      • Hex key
      • Wrench
      • Propane torch
      • Impact gun or hammer
      • Drill
      • Safety glasses
      • Heavy gloves

      You Might Also Like

      How to Set and Use a Torque Wrench
      How to
      Remove Rivets
      Best Ways to Remove a Snapped Off Bolt
      How to
      Calibrate a Torque Wrench
      How to
      Remove a Stuck Bolt
      How to Easily Load a Packing Tape Gun
      How to
      Make Velcro Stick Again
      How to
      Open Cable Ties
      How to
      Make a Rubber Band Ball
      How to
      Hang Something on Brick
      How to
      Use Lock Washers
      How to
      Install Grommets
      How to
      Install a Rivet Nut
      The Easiest Ways to Apply Command Strips or Hooks at Home
      Advertisement

      References

      1. http://www.popularmechanics.com/home/skills/auto-home-improvement-diy/how-to-free-a-rusted-bolt
      2. http://www.mgaguru.com/mgtech/universal/ut102.htm

      About This Article

      Thanks to all authors for creating a page that has been read 68,721 times.

      Did this article help you?

      Advertisement