Cant get roll bar bolts out!

[firefyter]

Trying to remove bolts from 85 CJ roll bar, did they use star bolts from the factory or did some dillweed put them in later. Mine are star bolts and they suck, worst idea ever for bolts, they strip before loosening and not one of them is loose yet, any ideas? Have wd 40;d them to no avail. Might have to torch em off but will leave studs in the threads to be removed.

 

[Purple77CJ7]

I would torch everything and use regular nuts and bolts when reinstalled. If bolts are that bad check you floor and wheel wells. My jeep was pretty bad, carpet was all that was holding the roll bar. Try heating bolts and let it cool just a little bit and see if that helps with the wd40.

 

[Jimbos76cj]

Have a welder to use? I would find the biggest grade 8 bolt possible, bevel the edge really good then weld the good bolt to the old head. The heat will help loosen it and the bolt will allow you to use a wrench to unbolt it. This works good for your windshield stars and door hinge bolts

 

[Jimbos76cj]

Also wd40 is not the best stuff to loosen stuck bolts. The some pb blaster or knocker loose.

 

[firefyter]

Thanks will try ideas above. They aren't rusted they look great, heads have shiny paint and all, just stuck.

 

[priceg]

Best money spent. Saves on medical bills too

 

[DaBannerman]

Make certain you're using the right tool. Mine came off my '86 without a hitch!

 

[Jimbos76cj]

Here's my post on the ones I removed from my local forum

I had 2 bolts that were rounded out so I decided to give the Weld and remove method a try..

It worked


I ground down the head of the torx bolt so it was bare metal.. ran the bolt on the wire wheel and ground a decent bevel on it. welded them together and it came right out with out any hassle. Im not sure if the heat from welding loosened it or if the weld was really that strong.. I really didnt think it would work

 

[firefyter]

Here's my post on the ones I removed from my local forum

Sweet. hope i dont have to do that 12 times!

 

[Jimbos76cj]

Sweet. hope i dont have to do that 12 times!

Probably will have to.. But thats about the only way get the threaded part of the bolt out of the hole. Or you can cutthe head off.. Drill and tryto easy out em.. That to me would be a pita. The Torx bolt have a good thick head on them and should have no problem taking the hear of a solid weld. There's my .02

 

[Jimbos76cj]

Also keep in mind that even though the heads of the bolts are clean the threaded ends are exposed underneath of the jeep so the can be rusted bad. That's also where you should be spraying the pb blaster or knocker loose.

 

[firefyter]

Also keep in mind that even though the heads of the bolts are clean the threaded ends are exposed underneath of the jeep so the can be rusted bad. That's also where you should be spraying the pb blaster or knocker loose.

Thanks again!

 

[cj7 dave]

howdy all. i had this problem before too. got smart, welded 5/8th nuts to top of bolts on roll cage.clean paint off of bolt and weld nut though center to bolt take air gun after it cools some and drive out and yes heat does help loosen glue and rust from bolts

 

[Pjiman]

welded 5/8th nuts to top of bolts on roll cage.clean paint off of bolt and weld nut though center to bolt take air gun after it cools some and drive out and yes heat does help loosen glue and rust from bolts

X2...but didn't bother removing the paint. Worked perfect.

 

[firefyter]

WHOO HOO got them out. Roll bar is out.

 

[Jimbos76cj]

So.. What was the secret.

 

[firefyter]

So.. What was the secret.

Welded nuts on bolt heads.