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Working_ZS · 04-24-2020, 08:18 PM

If the bolt is recessed like you say, you probably won't be able to get any fusion with stick or MIG welding a nut. It might be necessary to use TIG welding to build up the end of the broken bolt until it is proud of the surface, then weld a nut onto that built up section or just grab it with a pair of locking pliers. With TIG welding, you'll be able to very precisely control the arc and where you deposit filler metal, so you'll be less likely to mar the rack or weld the nut to it.

I went through this on a Dodge caravan that some previous mechanic attempted to replace the water pump on, but snapped off one of the 6mm x 20mm bolts. It was sitting below the suface of the aluminum timing cover/water pump housing and I had to build it up with my TIG welder, in order to grasp it with a pair of ViseGrips and thread it out. This took four or five attempts before I got good fusion with the bolt, so don't get discouraged if it doesn't work the first couple of tries.

04-24-2020, 08:18 PM	#4
Working_ZS Join Date: Aug 2016 Posts: 365	Sounds Like A Job For TIG Welding If the bolt is recessed like you say, you probably won't be able to get any fusion with stick or MIG welding a nut. It might be necessary to use TIG welding to build up the end of the broken bolt until it is proud of the surface, then weld a nut onto that built up section or just grab it with a pair of locking pliers. With TIG welding, you'll be able to very precisely control the arc and where you deposit filler metal, so you'll be less likely to mar the rack or weld the nut to it. I went through this on a Dodge caravan that some previous mechanic attempted to replace the water pump on, but snapped off one of the 6mm x 20mm bolts. It was sitting below the suface of the aluminum timing cover/water pump housing and I had to build it up with my TIG welder, in order to grasp it with a pair of ViseGrips and thread it out. This took four or five attempts before I got good fusion with the bolt, so don't get discouraged if it doesn't work the first couple of tries.
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