Safety First
Always use any relative safety equipment, follow all instructions with power tools and if in doubt consult a qualified engineer or mechanic.
Removing Old Rusty Stuck Bolts
I would always advise the use some sort of penetrating oil a couple of days in advice. If the bolt/nut still fails to come undone, tapping it with a hammer will sometime loosen the rust and help the process. Using a centre punch and hammer to try and tap the bolt undone can also help.
If this all fails and the head is now broken on the bolt, you may need to drill the centre of the bolt out. You need to be very careful here not to damage the item the bolt is screwed into. The best option is to use a left hand drill bit (which may undo the bolt as you drill) which is the core diameter or smaller of the bolt. If a left hand drill can not be sourced use a standard drill bit. Once you have drilled the centre of the bolt out, being very careful to stay central, you can try use a scriber to flick out the remaining bit of the bolt. Or alternatively, use a tap and run this down the thread, hopefully cleaning out all the remaining bits of the broken bolt.
Preparation for Assembly
Before and re-assembly work is undertaken ensure all parts are fully cleaned and checked for damage. Use a thread chaser or a tap (ensuring you’ve got the correct size thread) and run them down all the thread. Clean out the thread and check for damage/wear. Once you’re happy the parts are clean and in satisfactory condition you may continue, if they are damage then replacement made be needed or repair work undertaken.
Assembly
If using original spec bolts (i.e. high tensile or stainless steel bolts) then follow the manufactures fitting advice and using the standard torque settings. If you’ve decided to use stainless steel bolts where high tensile bolts where once fitted, then you need to use your own skill and judgement in the fitting process. Just as a guide stainless steel bolts are about 2/3 the strength of a equivalent size 8.8 high tensile bolt. Also due to the different material properties when the bolt is being tightened the stainless steel will course more friction on the thread giving you slightly false torque reading. Also when using either stainless steel bolt or screwing into cast iron, a small amount of lubrication should be used on the thread.
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