PLEASE HELP Get this bolt out....please....Im desperate...

[diarmaid]

Im at the end of my rope Please Help me.

I've been trying to change the front offside suspension strut on my 2000 Fiat Brava 1.2 sx since 3pm. Its now 8pm. I cant get this bolt out because it's burred Its a 13mm head m8. I tried a normal wrench, 2 different socket wrenches and bits. I soaked it in WD40 oil from both sides and left to sit. I tried a small and a large vice grips and everything just rolls off this damned bolt. I was supposed to be on a 'date' with SWMBO who is being understanding but hurt because Im trapped 15miles from home until I can get the new suspension on. This should have been a 30min job. Please suggest something Im desperate....you can see where I even tried grinding down the side to get a grip with the vice grips but that didn't work because there isn't enough space to get the grinder in to do another side.......Im afraid to just grind off the top of the bolt because then if the threads are stuck I'll have nothing to grab to get the rest of it out, I do have spare bolts to fit. The nut on the back is welded in place........help...........please.....all I can do is view this thread until I get a suggestion...
I also thought of drilling it out but I dont have a tap & die set to get one back in....

[RTP_Burnsville]

Could you grind a slot in the head for a slotted screwdriver and maybe use a vise-grip attached to the screwdriver as a wrench to rotate the screwdriver?

I just had a similar experience with a countersunk bolt yesterday in a drill chuck. Ended up cutting the chuck apart with a small rotary grinder and cutoff wheel. Once that was out of the way I put a slot in the screw head which allowed me to get the thing out.

Good luck.

[Al_The_Man]

Is there a reason you cannot grind the head off, and will this allow the unit to come off complete with welded nut?
There appears to be quite a long thread sticking out of the nut, this will then be accessible to use alternative methods to remove the broken stud, like putting some heat on it.
I am assuming that the whole piece in the last photo comes off complete once the head is off? Unless I am reading it wrong.
Al.

[NC Cams]

Try using a Snap-On, flank contacting, 1/2" 6 point socket - you might have to file down the flats a bit more and then "pound" the socket on.

If that is not an option, cut off the head and remove the surrounding housing - then grip the stud and be sure to apply heat to the housing the stud is stuck in.

To prevent a future problem, use Anti-Sieze at reassembly and curse the OEM for not using the same stuff when they put the bolt in at the time of manufacture.

[mxtras]

Impact always helps.

I have had success in this situation using a sharp chisel or even a center punch - hit the screw head off-center and in the direction you want to go to loosen the fastener. I would not do this while it's hot - use heat to help get the penetrating oil under the head and into the threads, let it cool a bit and then smack it!

Good luck! If all else fails, either drill or grind the head off.

Scott

[carlnpa]

I think you're at the point where you can pound on a 12mm socket.

[pauluk]

This is going to sound real silly, but are you sure that it has'nt got a left handed thread. I had a similar problem on a ford suspension bolt, it was easy when i turned it the other way.

[pauluk]

ok ignore that last post i just had a better look at the pictures,

[fkaCarel]

By now his wife should have lost faith in world wide first aid and called a cab.

Carel

[JPMach]

Smoking wrench always works, one way or the other. :-)

Or if you have a welder you can always weld a nut on top of the head to get a fresh bite.

JP

[mxtras]

or - put the car on a CNC machine and mill it out.

Whaddya think?

This is a CNC forum, right? Was this a trick question? What did I win?

Scott

[diarmaid]

THE EPIC STORY OF DIARMAID AND THE BOLT

Diarmaids dad arrived just after posting this thread and almost instantly suggested the same idea as RTP_Burnsville....Eureka! So Diarmaid then went to work with two hacksaw blades taped together for over an hour carefully cutting a slot into the bolt head in the confined space. Diarmaid had previously tried a 12 socket but although the bolt head was a wimp and burred easily around the edges, it was an olympian and just wouldn't give when Diarmaid tried the 'pounding release method'. After placing every conceivable type of leverage into the newly cut slot, using every conceivable type of hammering, Diarmaid had to beat a retreat, the bolt would just not surrender. Diarmaid shouted many profanities at the bolt to try and psyche it out, but to no avail. Diarmaid had to fall back onto the advice of Al The Man, one of his trusty allies in desperation, and turned to his faithful grinder. He told the bolt many times that it would come to this if it did not honourably surrender but the bolt was lacking any common sense. Diarmaid began grinding with avengence. Upon reaching the end of the bolt head the underlying plate fell to the ground. Diarmaid picked it up and grabbed the remainder of the bolt. Now lacking its head, and a shadow of its former glory, the remainder of the bolt was limp and twisted out easily by hand. 7 hours later, after an epic struggle, Diarmaid emerged victorious. He wishes to thank all his trusty allies for their advice in his time of need.
Unfortunately his date with SWMBO is cancelled until further notice and he his remaining in his current location, because darkness fell upon the scene of battle before he could replace the suspension strut.