How To Cut A Bolt In A Tight Space

Cutting bolts is tedious at the best of times, as it often means something broke or was incorrectly installed. However, when your work area is cramped, the situation becomes significantly worse. If you’re struggling to remove a stuck fastener, we’ll explore “how to cut bolts in tight spaces.”

How To Cut A Bolt In A Tight Space

While it’s not ideal to destroy reusable fasteners, several tools are available for cutting bolts, including bolt cutters, angle grinders, hacksaws, rotary tools, and blow torches. Thanks to the range of methods, you can start with the most drastic or the least invasive.

Unfortunately, nuts and bolts become stuck over time, whether through rust and wear on the points that spanners “grab” or because they are in a position where something else prevents access. 

If, for whatever reason, you can’t remove the bolt (especially if it’s blocked by something), then cutting is the next logical step. 

Step One: Evaluate The Work Space And Plan The Best Method For Cutting

Planning your attack is best before jumping in and cutting away at the pain-in-the-butt bolt. 

There are several essential questions to answer, including:

• What area is the bolt in? 
• How flammable are the surroundings? 
• What is it connected to?
• Do you have enough space to get a larger or smaller tool next to the bolt?
• Do you have access to the nut?
• How important is it to remove the bolt, and what are the consequences of damaging it?
• What tools are at your disposal?

Once you’ve answered these questions, you’d better know what to use for cutting the pesky attachment. The good news is that even with a limited tool arsenal, there are several workarounds, including:

Using A Bolt Cutter

As the name implies, this tool is designed for the job. However, they are limited by their size and the angle they cut at. Bolt cutters work best when cutting through a bolt shaft (the threaded part). 

These are a good choice if you can access a side view of the bolt.

Using A Hacksaw

A wonderful tool for cutting through most metal objects like cutting metal studs, the significant downside of a hacksaw is that you need sufficient space to cut in. 

Although you can get away with using the blade’s tip, you need enough room to move your arm back and forth. The rounded front must fit into the gap, and the blade makes contact with the bolt. There are mini-hacksaws, but they may lack cutting power for larger bolts.

Using A Hammer And Chisel

While more “barbaric,” a hammer and chisel might be the solution if you work with thinner bolts and nuts. Best used in conjunction with a cutting tool, you make an incision, then insert the chisel into it and hit the nut/bolt off of the object. These two are also useful in cutting an MDF.

Using A Grinder

An angle grinder is one of the most versatile tools every DIY enthusiast should invest in. These wondrous devices are perfect for cutting through bolts and nuts. Even cutting an asphalt using angle grinder is effective.

They are strong enough to cut through thicker bolts, and you can cut almost any part of the bolt. However, they require sufficient space for the disc to reach the item that needs cutting and produces a lot of sparks. Additionally, you’ll need the correct cutting disc.

Using A Rotary Tool

Rotary tools are also highly effective for cutting bolts in awkward, tight spaces. They require very little space for movement, and they cut through most bolts and nuts. The one downside is that they may take a while to cut through unlike cutting a paneling which is way faster.

Step Two: Position Yourself As Well As Possible Before Cutting

You don’t want to move back and forth in a cramped space, so having your tools at conveniently reachable places is essential. Try to keep them in a logical order of use so that you’re not fighting past the tools.

Alternative: an assistant that passes you the correct tools is wonderful. Unfortunately, it’s not always possible (especially if you’re inside a roof or other confined area).

It’s also essential to position yourself so that what you’re cutting does not go into your eyes/over your body.

Step Three: Use Your Tool Of Choice To Cut Through The Bolt

Start cutting the bolt with the appropriate tools once you’re in the position. While the situation dictates the most effective tool, many DIYers prefer the power tool option like using a circular saw to cut concrete blocks. 

A hacksaw-chisel combination is your best bet for a non-power tool option. Ensure that your hacksaw has the correct blade equipped and that the chisel is for metal working. Remember, several hacksaw types exist, including a “mini” version for confined spaces.

Start by positioning the saw so that the blade is against the bolt.

The amount of access you have influences the cut. If you can only reach the head from the top, you’ll need to cut through the middle of the head and into the shaft. Once through, use a hammer and chisel to knock out the cut pieces.

If you can reach the side of the head, try to cut the head free from the shaft. 

Try cutting the nut free from along the shaft if you can reach it. If not, cut out a section of the nut and use a hammer and chisel to pry it off.

Alternative: Using A Rotary Tool To Cut The Bolt

A small rotary tool is perfect if you can access various power tools, and a grinder is too big to fit into the gap. These tools come in different sizes and follow the same principle as a grinder.

You select the correct blade for the job and slowly cut through whatever part of the bolt is accessible. While it may take longer than a grinder, rotary tools get the job done eventually and are usually neater than a hacksaw’s work.

Final Step: Using An Oxy-Acetylene Cutting Torch For Stubborn Bolts

If, at first, you don’t succeed, burn it to the ground. Well, not so drastic, but using an oxy-acetylene cutting torch is the last step before looking for a new whatever you’re working on. 

If you’ve tried the various methods and none prove fruitful (or you couldn’t be bothered to waste time and the bolt is in a safe place), a cutting torch is the final solution.

Thanks to the incredible heat produced when mixing and combusting the gas, they oxidize (melt) metal and simultaneously blast it away with the gas moving out of the tool. 

Try Every Other Means Before Cutting The Bolt/Nut

Before cutting, try and make every effort to loosen the bolt first, as it saves you a significant deal of effort and frustration if you get it off.

There are several steps to take when removing stubborn bolts:

• Step 1: Start by using a socket wrench. While spanners require a larger space, a socket wrench with extensions might solve the issue.
• Step 2: Use an impact driver. Use an impact driver if the socket wrench doesn’t budge the bolt. These powerful tools often have enough torque and are convenient to fit into tighter spaces.
• Step 3: Add a lubricant. Many fantastic lubricants are on the market, from grease to WD-40 (and higher). If the bolt is rusted, lubricating it is often all it takes.

Frequently Asked Questions

Conclusion

Cutting through a bolt is not always the most fun job, especially when that bolt is in a hard-to-reach place. Fortunately, several tools allow you to achieve this objective, including hacksaws, chisels, grinders, and rotary tools. While power tools speed up the process, often a hacksaw is the best option.