What is the first step to take if a bolt or stud breaks off flush at the surface?

When faced with a situation where a bolt or stud has broken off flush at the surface, the most effective initial step is to drill a hole in the center of the stud. Drilling a hole provides a means to create a stronger grip for extraction tools, such as ease-out or screw extractors, which can be used to remove the broken piece more easily and effectively.

This approach is structured because drilling precisely in the center helps maintain the integrity of the surrounding material and prevents further damage. It also reduces the risk of misalignment when employing the extractor, which is essential for a successful extraction. Additionally, once a hole is drilled, various techniques, including the application of penetrating oils into the hole, can further assist in loosening the broken stud for easier removal.

Cutting the remaining piece with a saw may be more destructive and could damage adjoining components, while applying heat could warp or damage nearby materials. Using a hammer to knock it out may not be effective and could lead to further complication by possibly jamming the stud deeper into the material.