::sigh:: Apparently rust is bad. Who knew?

I decided to replace my faded, stained, scarred hood insert yesterday with a shiny new one from Merlin. So I began the arduous task of removing the hood insulation and the 14 bolts and the windshield washer hoses and sprayers and stuff...what a PITA.

I noticed that one of my drain hoses was missing...you know, the hose that is supposed to keep water from collecting at the front corners of the cladding. Also, needless to say, the drains were useless; being completely clogged with black gunky toxic waste.

Most frustratingly, though, was that 13 of the 14 retainer bolts were fairly easy to remove, although all of them had varying degrees of rust damage. The last nut would not come off the bolt, though. It just turned and turned in place. When I tried to remove the hood insert, the metal base of the bolt which is affixed to the bottom of the fiberglass insert just snapped off. Still in the hood. So now I've got a rusted flower-shaped metal disk on the top of my hood with a rusted bolt going through the hood, and no safe way to remove it. WTF??? How can I finish this Herculean task???

Have you hit the bolt with some PB Blaster? If not, give the bolt a blast and let it sit for a while before trying to remove the bolt. Another option would be to heat the bolt with a torch to try and knock the rust loose, but that could put your hood in danger. The only other thing that I can think of would be to cut the bolt off since the new insert should have bolts attached to it.

Good luck and keep us informed.

Months ago i removed the insert to see how it looks under.........Damn it !

Lot of accumulated dirt were under it,the drains were completely clogged as yours & one of the metal was off the insert; I didn;t had an idea to glue it back but use gorilla glue.

Then,to avoid gunk accumulating under the insert i placed soft weatherstrip around the edge on the hood where the insert goes & so far it has done a good job.

I tried (carefully) to simply break off the bolt...no luck, and I don't want to deform the sheet metal on the hood itself. I cannot cut it, as the nut is tight up against the bottom of the hood (no space to put a cutting tool). And PB Blaster probably won't work: it looks like the nut is completely fused with the bolt, and the bolt itself is flush on top with the flower-shaped disk on the outer surface of the hood. It just spins, with nothing to grab onto to try to force the nut to turn. Damn.

And yes, the metal underneath the insert is effing disgusting. Dirt and gunk and bugs and gross stuff. I guess roads are dirty places to drive. Dirt roads, too. :)

The only thing I can think of is to hold the screw from beneath to keep it from turning and drill out the top. Start with a small bit and make sure it is centered, and increase the bit size until you've drill enough material off the top to pop off the disk.

I had the same problem. to remove, just fold two of the tabs till they touch. clamp them together as close to the hood as you can with a vice grip, then hold that and twist the nut till it snaps in half.

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Originally Posted by Cobrajet

The only thing I can think of is to hold the screw from beneath to keep it from turning and drill out the top. Start with a small bit and make sure it is centered, and increase the bit size until you've drill enough material off the top to pop off the disk.

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If Orion's idea doesn't work because of material weakness due to rust...(if the "flower" disintegrates)

I was thinking along the same lines, except where C-J indicates a drill bit or anything related to drilling, substitute mini grinder or dremel...:smack:

If you can support the bolt head from underneath, & protect the surrounding paint on top with duct tape/cardboard, then proceed CAREFULLY with a mini grinder or dremel, you should be able to grind off the "flower"...:flower:

Same idea, different tool...:_wrench:

:luck:

Now you have three choices...four if you would give explosives any consideration...:smilewink

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Originally Posted by Ldub

Now you have three choices...four if you would give explosives any consideration...:smilewink

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Hydrochloric acid... that's five!

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Originally Posted by Cobrajet

Hydrochloric acid... that's five!

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I like the way you think...:yesgray:

A well placed, small cal. rifle round would also be effective, but would require removal of the hood...maybe.:naughty:

This here's Texas. I like the gun idea.

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Originally Posted by PHO2GR4

This here's Texas. I like the gun idea.

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:supercool:yes:

lol take the hood off and take it with you to the shooting range ..get you hunting rifle and blow that bolt out ...lol.. oh take a video....
j/k
the drill idea will work ..Ive done it a ton of times on old builds

I think I would cut the bolt off just below the nut with a dremel or similar. Then drill the bolt out at the center of the nut. That way, you are working under the hood and not from the top, just in case you slip. Once you drill the bolt out, it should break easily enough...

You should be able to cut it off with a small Dremel cutoff bit. Or, you could drill it out.

Nice to see you on the forum, Eric!

Bart

The vise grips idea will work . the bolt will break right off. shawn

I'll take it down to my local mechanic type place, and have them drill it out from the top, then snap it off once its structural integrity has been compromised.

I'd do it myself, but I'm not qualified. I think I'd know which end of the drill to use...isn't it the gun-looking tool with the pointy spiral-y thingie that spins around rilly rilly fast and makes that sound like you hear at the dentist?

More updates soon!

I think I'd just put a glob of epoxy on the thing and reinstall the insert. Maybe the epoxy will be strong enough to hold it in place for the next time you try to remove the nut.

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Originally Posted by psychos2

The vise grips idea will work . the bolt will break right off. shawn

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I have had a few of them break while removing the insert, and have also had them come off the insert . Trust me it is a waste of time to drill them if you grip them with vise grips and turn the nut with a socket , either the nut will come off or it will break the bolt ,either way you do not need to drill them. shawn

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Originally Posted by PHO2GR4

I'd do it myself, but I'm not qualified. I think I'd know which end of the drill to use...isn't it the gun-looking tool with the pointy spiral-y thingie that spins around rilly rilly fast and makes that sound like you hear at the dentist?

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:laugho::laugho: ROFL ...Sounds like me!.....:laugho::laugho:

Took it to Rebreu Auto Body just up the road from me in north Austin. One of the techs took my keys, sped off, came back three minutes later with NO RUSTY BOLT. I tried to give him money but he wouldn't take any! And I'll never know how they did it... :(

Now I get to reverse the procedure and try to get the new insert installed right-side-up. Photos when available.

Eric, put a little dab of grease on the threads and you will never have another problem

I get mine repaired with just sand paper and epoxi, It's been about 6 month since then and it still looking good. I'll post some photos.

I still need to pull mine & repair the one broken stud. It's the back corner on the drivers side. When it gets cold outside, it starts warping upward on that corner.

t4b, I had the same problem a while ago. Just take the insert off of the hood, lay it face down on a nice soft surface (so you don't scratch it), remove the old "glue" from where the stud has pulled away, and re-glue the stud back down. I used JB Weld on mine and they haven't moved in over two years.

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Originally Posted by MSHardeman

t4b, I had the same problem a while ago. Just take the insert off of the hood, lay it face down on a nice soft surface (so you don't scratch it), remove the old "glue" from where the stud has pulled away, and re-glue the stud back down. I used JB Weld on mine and they haven't moved in over two years.

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Pretty much as I had planned ... BUT ... the stud is broken. I need to find a replacement & it's not a very common part. I plan on stopping by Fastenal (SP?) soon to see what they offer.