How to remove stuck well cap?

F

Fordiesel69

Joined
Sep 10, 2005
Messages
2,545
Location
Erie, PA
Have a friend that i am helping replace a 2 pipe push / pull jet pump and convert over to a single pipe submersible pump. It is estimated to be a 40 - 60 ft well.

I am unable to figure out how to get his rusted well cap off, and so looking for suggestions. The local pump supply shop says not to let the bolts snap off and fall down as parts of the clamp would fall down and bind up in the well casing.

Suggestions.

cap1.webp
cap2.webp
 
I would try wire brushing the top. Applying very little penetrate directly on the bolts. Not much at all. Let it sit for a while so it starts working it's way under the bolt head. Then hit it with a torch to expand the metal slightly, while putting a wrench on it and working it both ways. Hopefully it gives before it snaps.,,
 
I did all that (not shown in photo) I used pb blaster and I can tell that if i use a breaker bar, the bolts will just snap. This well used to be outdoors, and in 1990s they enclosed it.
 
Can you post a depiction of what the underlying clamp looks like under the cap? That would give us a better idea of what the risks are and perhaps a way to mitigate them.

Given what you have stated in Post #3, my first thought is to grind/cut away ~1/4 of the cap (using a strong magnet w/lanyard to capture it) to expose part of the internal clamp. Then, you can attempt to capture the clamp assembly with a wire lanyard before snapping off the remaining bolts.
 
Might have to cut it or the casing below it.

There's a similar arrangement inside and a rubber block between that squeezes the cases when tightened.

If the metal pieces fall down, it'll wedge the pump.

It's not a good design, not sure why it's still often used. Definitely shouldn't be used outdoors uncovered as it's not sealed from rain, dirt, etc dropping in the well.
 
In addition. Once you remove the hoses/piping you may be able to pry the whole thing out in one piece. These are just friction fit to the inside of the casing. Of course all of the inside piping will need to be pulled as well. Currently it appears to be in a bind from the external piping pulling down on one side.
 
Fordiesel69 said:
Have a friend that i am helping replace a 2 pipe push / pull jet pump and convert over to a single pipe submersible pump. It is estimated to be a 40 - 60 ft well.

I am unable to figure out how to get his rusted well cap off, and so looking for suggestions. The local pump supply shop says not to let the bolts snap off and fall down as parts of the clamp would fall down and bind up in the well casing.

Suggestions.

View attachment 232098View attachment 232099
Click to expand...
Ive read that using dry ice will shrink the bolts enough to let them break free. I know that the huge bolts that hold bridge sections together come packed in dry ice and after installation expand to create a tight fit.
 
I cannot get a photo of the clamp arrangment as that design has not been used locally since the 1960's.

An externally bolted cap is what has been used locally.

It is not in a bind from the external piping. It is loose and I can rotate it around. That is how I was able to heat the bolts.
 
I've replaced quite a few jet pumps, but never pulled any of the underground parts.
What is the point of changing from a jet pump to a submerse on a 40-60ft well?
Or its bad and you have to replace it all anyway?

If its friction fit can you just muscle it out with prybars?
put a couple 200lb magnets on top?
 
The jet pump is not rebuildable. It is beyond repair and a new one is double the price of a submersible.

A submersible is 20 yr lifespan. Chinese jet pump is 5 yrs max, and a good meyers is probably 10 real world in this damp well house, maybe less. Everything in this well house is converting to pex as the moisture is not able to be controlled. Everything rusts and corrodes.
 
Last time I bought a 1/2 HP wayne cws50(2015) was $215 looks like $270+ Now
a 3/4hp in 2016 was $250 now $350

Ouch.
 
Since the cap is split into two halves, can't you just snap off the bolts and remove the back half to expose the expansion plug clamp assembly? The bottom ends of the snapped off bolts can't drop into the well cavity since they are rusted in place within the bottom plate of the expansion plug. The remaining (3?) bolts and the wiring would prevent the expansion plug from dropping.

Once you can access half of the expansion plug, you should be able to rig up a lanyard to capture the clamp before snapping off the remaining bolts.
 
That is a split well seal, different than a well cap. You do NOT want to loosen the bolts to the point that the bottom plate detaches and falls down to the pump and wedges in, making it EXTREMELY difficult to remove the pump.

Detatch the top water lines, use a flat pry bar to force the entire seal and pipe up and out. Remove the seal and well pipes as an assembly and then R&R the top assembly. Some spray silicone lubricant on the rubber part might help.

1721928025011.jpeg




Try this first - you already have a big gap in your top picture:
1721929021067.jpeg


If that does not work, use a floor jack and your imagination to push up on the seal edge:
1721929066854.jpeg


All else fails, you could cut the well casing a few inches down.
 
Last edited:
Fordiesel69 said:
I cannot get a photo of the clamp arrangment as that design has not been used locally since the 1960's.

An externally bolted cap is what has been used locally.

It is not in a bind from the external piping. It is loose and I can rotate it around. That is how I was able to heat the bolts.
Click to expand...
So it's freely rotating and you still want to take it apart? Why is that? Just pull it.
 
take a hammer and tap firmly on it (cover) first,the get some CRC Freeze off and spray on it and down bolt holes also providing you can get them out if not tap or pound on bolts to remove them.when attempting to remve use a large pipe wrench and use a twisting motion back and fourth,, a air zip gun with a blunt tip may also work to crack seal (vibration),,good luck.
 
I have removed quite a few of them over the years. I loosened the bolts and the took a claw hammer and worked the claw around the outside working the seal up a bit at a time. Never had one I was unable to get out.
 
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