Rusted bolt...HELP?

[franky dB]

I am trying to remove the fuel tank support bracket. I have supported the fuel tank, and removed one of the bolts. I am having problems removing the second bolt as the head is so rusted it crumbled and rounded when i attempted to undo it. I am now left with a rounded bolt. Anyone got any ideas how i can get it out?




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[spongy]

Bud i would try some mole grips on it first....if that fails then use a hacksaw blade on it.

[shep1001]

Stud extractor. Drill centre of the bolt to match the size of the extractor to be used, tap it in the end of the bolt and twist with mole grips/spanner. It should 'bite' into the bolt and loosen it. Use some heat and WD40 first to make things a little easier first.

Shep

[Targarama]

Nice sharp tap with a hammer and chisel?

[spongy]

Got to say bud looks like you have the car low to the ground there for working on.can you not get her any higher?makes things a lot easier.

[franky dB]

The main issue is the bolt is so close to the fuel tank there is not enough room to get a drill in at the correct angle. It would be far simpler if i could remove the fuel tank, but the bracket i'm trying to remove needs to be removed to get the tanks out. I cant even lift the tank up to give more room as its pressed right up against the body. I may have to fabricate an extra long drill bit to give me the clearance away from the tank, then i will be able to get a stud extractor in.

[PIW19]

Would suggest a Dremmel with a small grinding disk to take the head off the offending bolt. Won't be quick and likley to take more than one disk but once the tanks out of the way you should have a small length of the original bolt showing to grab with mole grips. Should come out given the tension has been relieved on the thread. That failing it will be a drill and re-tap

Oh, and use stainless fittings on putting back together.

Best of luck

[franky dB]

Well, after trying almost everything I finally got the offending bolt out. Ended up grinding half the head of the bolt and then I managed to get some grips around it.

I now have the issue of a very rusty fuel tank support bracket to deal with. I think it is past blasting and re-powder coating. Does anyone know a decent fabricator in the south who could make me up a new one?

This is what it looked like after I removed it.




This is what it looked like after 5 mins picking the flaky powder coating off with my bare hands, no tools were needed it was that bad.






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[RedSpike66]

Speak to clive f...... he seems pretty good with his hands (so i've heard - he never touched me ur honour !!)