How to Fix a Broken Weld Nut

Learn how to fix a broken weld nut in just a few simple steps. Whether you are a beginner or a professional, a fractured weld nut can be difficult to repair. We’ll guide you through inspecting, reassembling, welding, and finishing the weld nut so that it can be re-installed and secure. With our help, your weld nut will be back to its original condition.

Causes of a Broken Weld Nut

1. Improperly Installed

A broken weld nut can be caused by incorrect installation. This may include wrong hole size, threading, orientation, torque, or any other mistake during the installation process.

2. Excessive Vibration

The weld nut can break or distort if it is not tightened correctly or exposed to vibration from heavy machinery. Typically, lightweight workpieces or equipment do not experience such issues.

3. Poor Welding Technique

False casting can cause problems with the weld nut, as it must be precise and robust enough to hold it securely in place. It is crucial to ensure that the welding is done with the correct amount of heat, as excessive welding can also cause the weld nut to break.

4. Corrosion

When a weld nut is not adequately maintained or for any other reason, corrosion can occur and weaken the welds, making them more susceptible to breaking.

5. Defective Material

Before buying a weld nut, inspect it for quality to ensure it won’t ruin your project. Poor-quality or counterfeit weld nuts can lead to disastrous results, so it’s important to make sure that you’re getting a genuine, high-quality product.

How to Fix a Broken Weld Nut (3 Methods)

Fixing a broken or softened weld nut can be challenging, as they are usually in tight, narrow spaces. To make this process easier, here are some steps to follow:

Remove Broken Weld Nut

Method 1

If you are able to remove the bolt from the weld nut, then you can follow the steps of this method. 

1. First, unscrew the bolt, spray some penetrating oil on the weld nut, and give it time to work.
2. Next, insert a large pry bar into the weld nut and apply pressure. This should cause the weld nut to move beyond its current position.

Note: If the light workpiece has a Weld Nut, it can be tricky to work with the pry bar alone. In those cases, you might need a friend to help you hold the workpiece steady. You can heat the Weld Nut with a heat gun.

Method 2

1. Start by spraying some Penetrating Oil on the weld nut and bolt joint. Follow the instructions on the packaging and wait for a while. 
2. Then, you can use a grinder tool to cut off some of the bolt’s parts. 
3. After that, hit the remaining part of the bolt with a hammer and apply more Penetrating Oil if necessary. The impact should loosen the Weld Nut, allowing you to take it out.

Note: Cut the part of the bolt down to a size that can easily be removed once the Weld Nut has been loosened.

If the bolt cannot be loosened from the Nut- 

Method 3

1. Begin by spraying Penetrating Oil on the area and letting it sit for a while. 
2. Then, use a grinder cutter to cut off the head of the bolt and make it flat.
3.  After that, make a hole in the center of the Nut with a drill. 
4. Finally, place the Pry Bar inside the hole and use pressure to loosen the Weld Nut.

Install New one

I hope that you have successfully removed the Broken Weld nut. To replace it, you can use either of my suggested methods. Choose the one that best suits your needs.

Method 1: Install Hex Weld Nut

1. Find a drill bit the same size as a Hex Weld Nut to make a hole in the metal.
2. Drill in the desired location for the Nut.
3. Insert the bolt into the Nut and hold it in place with pliers.
4. After the Nut is securely flashed with the workpiece, weld the Nut and remove the bolt.
5. Use a grinder to ensure the welds are level. For safety, wear work gloves.

Method 2: Placed and Weld a Tap-base Weld Nut

1. Then, mark the tab-weld Nut on two sides of the existing hole on the workpiece in the two-projection size.
2. Use a drill to create two extra holes according to the size of the projection.
3. Insert a slightly smaller bolt with a galvanized iron wire into the weld nut and the central hole.
4. Secure the bolt with a plier, then bring it directly into the extra hole of the projection and weld it in place.
5. Finally, remove the small bolt and install the correct size bolt. 

Done!

Is It Safe to Use After Fixing the Broken Welding Nut?

I need to look at your broken weld nut to answer whether it is safe to use it after fixing it. 

1. Careful observation is necessary to see if there have been any changes to the shape of the Nut,
2. If it has not been rusted and thinned, and 
3. If the internal thread of the Nut is still intact. 

By looking at these details, you can determine the safety of using the Nut after fixing it.

If you can change the Nut, replacing it is the best way to ensure that no doubt remains.

Conclusion

If you’ve ever struggled to fix a broken weld nut, use the tips in this article and get the job done fast! Comment below if you have any additional information or advice, or share this article with your friends if you found it helpful.