Rusty Nuts!

Technical Area Body, Interior & Styling
2

Just brought my second MK1 as I sold my last one a couple of years ago and really wanted another but one I could spend some time on doing up.

This time I got a 93 1.6i which mechanically is great. Just needed new plugs, HT leads, etc.

The problem is with the body. I knew it needed a new front wing when I brought it as it is badly rusted where it meets the front bumper. It has also had a small bit of welding done at the back of the inner cill. I got it very cheap as i knew I would have to spend a bit of money doing it up but want to keep the car for some summer fun etc. I started to take off the front bumper to allow me to take the wing off but just about every bolt is so badly rusted that on some the hex head is not even left! Did the usual and sprayed with WD40 and left them a few days but on trying to remove them most just sheer off. I know this means drilling the remains out but does anyone have a better way of removing rusted bolts. I tried to undo the 4 10mm bolts on the underside of the bumper but they would not budge and ended up hacksawing them off. if I drill the remains of the bolt out will I need to re cut the thread?

 So how do thers get round these problems. Is it easy to get new bolts and what would you recomend a sreplacements. it does seem crazy to use steal nuts when they are so exposed and bound to rust.

Look forward to any help

 

Cheers

 

Martin

3

the best thing for rust and bolts that are seized is to heat the nuts up if you can get to them or grind the heads of the bolts remove the bumper then do it of the car you will need some seirous heat from a oxy aceline torch so they are glowing red hot.then remove the bolts with mole grips you will find you can screw new bolts in if you work them in with oil or run a tap down them. if they are 10mm heads a 6 mill thread is the norm good luck with it as rust is a pain!

remember when you refit to use grease on the threads so if you have to remove them again it will be easy.

have fun

4

Thanks Mike

 the bolts on the bottom of the front bumper go through plastic so heat is not an option. I have brought a set of stud extractors and will try and drill the thread in use the extractors. Not sure if they will work as the bolts seem solid rust. last resort will be to fully drill out and re tap the thread. Such a lot of hassle to take a bolt out!

guess thats the fun of doing up an old car[:S]

 

Thanks for the advice

 

Martin

5

Plusgas is probably the best for rusty nuts.
If you do have to drill out studs, use a 5mm drill and also centre punch the stud if possible. Then use a tap to clean out thread.