The Dispatch | Expert | Scudo Hub

kenbw2

Administrator

From: Preston

Registered: 2017-11-26

Posts: 1,617

How can I remove this rusty old bolt shaft stuck in roof rack mount?

I've got a new bigger solar panel coming, which means I'll need to make use of the frontmost roof rack mount points.

Unfortunately the van came with a bolt shaft stuck in there, so I'm wondering how to get it out.

I know welding a nut onto it is likely the answer, but I have neither the skills nor the equipment.

I could also drill it out but that sounds risky for keeping the threads in place

Suggestions welcome!

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2000 Citroen Dispatch 1.9TD XUD9 Camper Conversion
1999 Citroen Dispatch 1.9D DW8 Disassembled Camper Conversion
1996 Peugeot 806 1.9TD XUD9 Spare vehicle
1998 Citroen Synergie 1.9TD XUD9 Snapped timing belt

Casper

Member

From: East Lothian

Registered: 2015-12-20

Posts: 2,180

Re: How can I remove this rusty old bolt shaft stuck in roof rack mount?

https://www.zoro.co.uk/shop/hand-tools/ … ac0a180513

Or reverse drill bit what also may loosen the thread when drilling but you could also just re cut the thread of you bugger it with a tap die set

JohnDragonMan

Member

From: Derby, East Midlands, UK

Registered: 2020-06-02

Posts: 456

Website

Re: How can I remove this rusty old bolt shaft stuck in roof rack mount?

well i always go for a blow torch in times of crisis. no dont set the whole thing on fire, just a small part of it.

really, get that thing heated up good and it will come right out. just note that you will have to re-paint where its scorched it but its nothing a bit of brush on metal paint cant fix.

pair of mini vice grips clamped onto whats theft of the bolt, then heat the outer up switching from one side then the other. keep having a go at twisting the grips. as soon as you get the thread "rocking" you are laughing. keep rocking it back and forth and it will come out.

i had hell with the ABS pump bracket. i snapped every bolt off on that but what was left soon came out with heat.

Last edited by JohnDragonMan (2020-07-29 01:37:28)

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- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: Internally rust proof the sills and subframe! both skins!!. There's always user serviceable parts inside. "Oh that shouldn't have happened".
My 2005 Dispatch Camper Project

kenbw2

Administrator

From: Preston

Registered: 2017-11-26

Posts: 1,617

Re: How can I remove this rusty old bolt shaft stuck in roof rack mount?

The blowtorch looked like the most promising option but I was hesitant to scorch the paint around it, but thanks for the tips!

At risk of making things worse I went to my trusty garage and asked him to weld on a nut and it was out in a few minutes. And suddenly it was out 

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2000 Citroen Dispatch 1.9TD XUD9 Camper Conversion
1999 Citroen Dispatch 1.9D DW8 Disassembled Camper Conversion
1996 Peugeot 806 1.9TD XUD9 Spare vehicle
1998 Citroen Synergie 1.9TD XUD9 Snapped timing belt

Chrissim

Member

Registered: 2020-08-09

Posts: 3

Re: How can I remove this rusty old bolt shaft stuck in roof rack mount?

Get yourself a Bolt removing tool.
Drill into the centre of the bolt with drill about 1-2 mm smaller than the bolt.
Screw in the bolt remover , it has a left hand thread .
Spray plenty of WD or silicon spray around the circumference of the broken bolt and let it sit for several hours.
You may want to make a trough with some tape  the bolt remover and it should unscrew the broken boltso the spray will pool and seep down the threads.
Then carefully turn the bolt remover and it should unscrew the broken bolt.
That's how the grease monkeys remove broken bolts.
Good luck

kenbw2

Administrator

From: Preston

Registered: 2017-11-26

Posts: 1,617

Re: How can I remove this rusty old bolt shaft stuck in roof rack mount?

Love the tip of making a trough of WD around it, I'll remember that for the future

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2000 Citroen Dispatch 1.9TD XUD9 Camper Conversion
1999 Citroen Dispatch 1.9D DW8 Disassembled Camper Conversion
1996 Peugeot 806 1.9TD XUD9 Spare vehicle
1998 Citroen Synergie 1.9TD XUD9 Snapped timing belt