When it’s time to remove a bolt or nut like this, you usually start by introducing it to the business end of a recip saw or a wire wheel — and then the real work starts. I’ve heard that the easiest approach is to weld on a nut or sawed-off bolt so that the remaining part of the bolt can be backed out, but I don’t have enough welding experience to know what alloy to use. According to some welders I’ve talked with, Messer Welding MG 600 will do the trick if the metals involved are steel; it provides the high tensile strength necessary to twist out a bolt that’s rusted stuck.
What would you use? Let us know in comments.
Photo from cheetah100 posted on Flickr.