Learning a New Skill with New Tools: Welding Nuts to Remove a Bolt
The Broken Bolt Problem
I’ve snapped more screws and bolts than I can count. Back on my 1995 Ford F-150, the passenger-side exhaust manifold was held on by several bolts — and one stubborn remnant that had turned into a stud. I tried everything to remove it with my then-meager tool collection. Nothing worked. The minor exhaust leak? I just lived with it.
Recently, the same story repeated on my second Honda Acty. While changing the thermostat, the third and final bolt snapped. Corrosion had done its job well. I tried various removal methods before deciding on the tried-and-true method: welding a nut onto the remaining stud. One problem — I didn’t have a welder and I didn’t know how to weld.
Getting the Right Gear
I wasn’t starting completely from scratch. I had some welding gear from a past project that never got off the ground. After researching, I decided a low-cost, simple flux-core MIG welder was the best fit for the job.
I settled on a YESWELDER from Amazon. With a coupon, it was just over $100 and came with a roll of flux-core wire worth $20 alone. The setup was straightforward: in about 10 minutes, I had the cables attached, wire fed, and was ready to weld. Preset wire feed speeds and voltages took the guessing out of it, although manual adjustments are possible.
I tried various removal methods before deciding on the tried-and-true method: welding a nut onto the remaining stud. One problem — I didn’t have a welder and I didn’t know how to weld.
Learning How to Weld
The last time I welded was in high school on a dump truck bed — ugly, weak welds all around. I turned to one of my favorite YouTube creators for a flux-core welding tutorial.
My goal was simple: weld nuts onto broken bolts to extract them. Strong, not pretty, welds. With pliers holding the nut over the remaining stud, I started welding, pausing briefly when needed.
Trial and Error
I went through 7 of the 8 nuts I bought. Three times, the new bolt sheared off again. By the seventh attempt, I had gotten the hang of it, focusing on deep, solid welds rather than perfection. Half of the broken bolt came out on that last try. After chasing the threads, I secured the thermostat housing with new stainless steel bolts from Amazon.
Essential Gear
The Takeaway
It was a lot of fun learning to weld, even for such a small task. Beyond finishing the thermostat, the real victory was realizing I could pick up a new skill and immediately put it to practical use. The right tools, a bit of patience, and a willingness to learn can turn frustrating roadblocks into victories.
Next time I snap a stubborn bolt, I’ll be ready. Sometimes, what looks like a problem is just an opportunity to expand your skills — and to have a little fun in the garage.
Heads up: a few links here may be affiliate links. Using them supports Fix Up Fleet without costing you extra — and lets me buy the next batch of parts for new projects.
I’m a lifelong DIYer keeping a fleet of cars and trucks on the road — from Subarus to a ’69 MGB GT to a dump truck. Fix Up Fleet is about budget-minded fixes, practical advice, and having fun with every rig in the garage. Buy it, fix it, drive it, repeat.
