best tool to cut rusted bolts/nuts

[KurtG]

I am renewing my trailer and there are a lot of rusted bolts/nuts. The frame of the trailer itself is in very good condition outside the roller assembly brackets and springs. I am painting the trailer and want to replace the 4 keel rollers, bunks, and springs.

I broke ~1/2 of the rusted bolts torquing on them, but need to cut the rest off, as there is nothing left of the rusted nut to get a grip on.

I have a dremel. Would that work if I get a cut off bit or should I buy a larger grinder? I assume buying a tool will still be cheaper than having to take the trailer to a welder.

 

[Rowroy]

Re: best tool to cut rusted bolts/nuts

A Dremel will work, but will take forever. I would use an air-powered die grinder with a cutting wheel or an electric 4 1/2" angle grinder with a cutting wheel. I use both and they work well for cutting almost anything.

Another, cheaper, option would be a hammer and chisel.

 

[tashasdaddy]

Re: best tool to cut rusted bolts/nuts

actually for $10-15 dollars a welding shop will torch the off in no time. i have used Sawsall with metal blade, grinder, etc. now i just take it down to Pat, and in 10 minutes everything is off. worth every cent, and no busted knuckles.

 

[jlinder]

Re: best tool to cut rusted bolts/nuts

I remember seeing a nut cracker tool a long time ago. It worked like a nut cracker.

It fit over the nut then screwed down and a wedge went into the nut and broke it.

Anyone have experience with these?

 

[Rowroy]

Re: best tool to cut rusted bolts/nuts

I remember seeing a nut cracker tool a long time ago. It worked like a nut cracker.

It fit over the nut then screwed down and a wedge went into the nut and broke it.

Anyone have experience with these?

Yep. I have a whole set and have had moderate success with them. I only use them if I can't access the nut with a torch or cutoff wheel. THey are ideal if you want to save the stud or bolt the nut is on.

 

[KurtG]

Re: best tool to cut rusted bolts/nuts

I am not going to get to the box store before the weekend. I will try the cold chisel first since there isn't much metal left on most of the nuts/bolts and I have the tools. I also have a sawsall and will see if I have any of the metal blades (I think I broke my last one cutting off a metal ground post in the yard).

Depending on the costs of blades, I might give the sawsall and the dremel a shot before buying a grinder.

I'd like to avoid taking the rig on the road if possible to the welder and having one come out to the house is going to run a lot more than a grinder.

 

[reelfishin]

Re: best tool to cut rusted bolts/nuts

I normally use an exhaust cut off tool which requires an air compressor but my next choice would be either the 4 1/2" grinder with a cut off wheel or a sawzall with a 14 tpi blade. I rarely go for the torch since I can make a much more precise cut and not worry about any damage to the galvanization or paint on the frame. I've also used bolt cutters as well if I can get at the bolt with them. A nut splitter can work but if the nut is badly rusted away it probably won't grip the nut well enough to take hold properly and do it's job.

 

[NelsonQ]

Re: best tool to cut rusted bolts/nuts

I'd recommend an angle grinder (just picked one up today at Costco for $20 CDN) including case, grinding disks, and cutoff disks. Cheap alternative.

 

[Mwp909]

Re: best tool to cut rusted bolts/nuts

I was at Tractor Supply today and they have cut off wheels that fit your drill a pack of 5 for $9.00. You could try that.

 

[KurtG]

Re: best tool to cut rusted bolts/nuts

Thanks for all the suggestions, I'm more confident I'll be able to pick up something to do the job this weekend.

In the meantime, the boat is up on blocks in the garage and I've been stripping the bottom paint, that is not any better job than working on rusted bolts on the trailer.

 

[MrBigStuff]

Re: best tool to cut rusted bolts/nuts

A lot of good suggestions already. One method I have used to great success (when all I had was hand tools) was to use a pipe wrench on the rounded off fastener. The pipe wrench has an advantage in that it gets tighter and bites in harder as you apply pressure. I would just snap them off using the following; Put an offset wrench on the good side of the bolt/nut combo. Rotate it so that it rests against the frame or something solid that will prevent it from turning. Use a pipe wrench on the other side with an appropriate length of pipe on the handle to gain significant leverage. The nut will come off or the bolt will snap- either way it's off. I have a variety of pipe wrenches from 3" to 3' so they fit just about any scenario.

Heat helps alot. A MAPP torch can get the fastener hot enough to help it come off. I've used my oxy/acetylene to heat fasteners cherry red and even the most stubborn come off fairly easily then. This when I didn't want to damage the pieces that were bolted together by cutting.

 

[Tiki35]

Re: best tool to cut rusted bolts/nuts

I have also used a reciprocating saw with metal blades that has worked well.

 

[jkoce]

Re: best tool to cut rusted bolts/nuts

for tight locations, i can vouch for the dremel. make sure you get the fiber reinforced cut off wheels NOT the emery type wheels.

i have used the 426 wheels to cut through stainless steel, hardened steel, etc. it takes a while, but in tight quarters these babies are great!

 

[tashasdaddy]

Re: best tool to cut rusted bolts/nuts

the above wheel works great, just expensive, i have used them to cut the race off the spindle. but one wrong move and they disintergrate.

 

[MikDee]

Re: best tool to cut rusted bolts/nuts

for tight locations, i can vouch for the dremel. make sure you get the fiber reinforced cut off wheels NOT the emery type wheels.

i have used the 426 wheels to cut through stainless steel, hardened steel, etc. it takes a while, but in tight quarters these babies are great!

the above wheel works great, just expensive, i have used them to cut the race off the spindle. but one wrong move and they disintergrate.

I use these a lot myself, but as TD says, watch out for that. Otherwise, I use a 4" angle grinder.

 

[jkoce]

Re: best tool to cut rusted bolts/nuts

I use these a lot myself, but as TD says, watch out for that. Otherwise, I use a 4" angle grinder.

forgot to mention that! you guys are right...have to cut straight with the wheel, once you start. if you try to angle the wheel once the cut has started, it'll prally snap the wheel.

 

[kenmyfam]

Re: best tool to cut rusted bolts/nuts

Disc grinder with a "biscuit" cut off wheel = offending article gone.

 

[Wills03]

Re: best tool to cut rusted bolts/nuts

I use angle grinder with thin cutoff disc. Hold steady with two hands and cut strait thru end of bolt and 90 - 100 percent thru nut making two half nuts.

Insert flat screwdriver in slot cut in nut and twist. One or both halves of nut will pop right off bolt.

Takes 30 sec max. You will need new bolts & nuts. Tractor Supply sells them by the pound very inexpensive.

 

[jonesg]

Re: best tool to cut rusted bolts/nuts

Just got an 18v DeWalt sawzall and 1/2" drill combo at depot for $179 in a case, with a metal blade I removed 1/2" stainless bolts in 20 seconds.

I like the 4 1/2" angle grinder but the sawzall was impressive for speed , as long as you can get the tool in there, otherwise its dremel time.

 

[mthieme]

Re: best tool to cut rusted bolts/nuts

A hot wrench would be my first choice followed by a grinder.