If a broken bolt cannot be removed with an eze-out, what action should be taken?

• A. Use a larger eze-out
• B. Over-drill the broken bolt and replace with a larger bolt
• C. Drill out the bolt and install a stud
• D. Weld a nut onto the broken bolt

Answer: (B)

When a broken bolt can’t be removed with an extraction tool, the practical move is to remove the broken piece by drilling it out and then restore the fastening hole with a larger bolt. Drilling past the broken fragment clears the obstruction and avoids further damage to the remaining threads. Once the hole is clean, re-tap to a larger size or use a larger bolt so you still get the required clamping force and thread engagement. This approach is more reliable than forcing another extraction attempt, which can snap tools or worsen the damage.

Why not the other options? Using another EZ-out is unlikely to succeed once the bolt is broken and stuck, and it risks further damage. Drilling and installing a stud changes the repair method and may not provide the needed strength or alignment in every application. Welding a nut onto the broken bolt can work in some cases, but it often isn’t feasible or safe due to heat and accessibility concerns. The over-drill-and-replace-with-a-larger-bolt method directly restores a solid connection with appropriate thread engagement.