Bolt help

[DWBOX2000]

The gas cover on my wife’s car fell off. We got a new cover but the two bolts that hold it on our rounded. I believe they were either Allen head or one of those t something bolts. Before even going in, I could see that they are rusty and rounded. I tried my Allen and t (torx?) but they didn’t catch. Suggestions for getting out. For Some reason, I can’t post pictures.

[rfuerst911sc]

Is there any bolt head sticking up that you can lock some vise grips on ? You may have to drill them out with reversing bits .

[herr_oberst]

Hit it with penetrating oil, give the chemicals a chance to work, then try wedging in a slightly larger size torx, (or allen)(or flat blade screwdriver). Also, when you get the tool in and it has good purchase, try tightening it just a scootch - sometimes that will break the bond.

Slow and steady.

[GH85Carrera]

They may have been Torx bolts. You need the proper size torx adapter to get them out. If they are rounded, and easy out that has new sharp edges may do it.

It will suck for sure. Good luck.

[Nickshu]

Cut a slot in it for a big screwdriver. Penetrating oil and try to turn it. Maybe even put a crescent wrench on the end of the screwdriver. Worst case the head breaks off and then you can drill it out and tap it for a new bolt. I'd say use heat but I assume this is a painted area.

[blucille]

There are a variety of slightly oversized and tapered torx (and other) screw removers. Try a few, I’ll bet one of them would get the job done. A little heat, penetrating oil and an impact tool. Manual or power all will help the process.

[DWBOX2000]

Thanks everyone.

[javadog]

They were probably torx head screws, those tend to be used on a lot of vehicles now.

The first thing you need to do is clean them up and see what you’re dealing with. Sometimes you can clean out the crusty rust and get a tool to engage them again. Just make sure you’re using the right size.

If they are completely fubar’d already, read on.

You need to remove the heads by drilling. Select a bit size that will allow you to use what’s left of the recess in the head to center the drill. You want to end up with a start to the hole that centers the point in the center of the fastener. Next, take a bit that you estimate is no bigger than the root diameter of the screw and drill into the shaft of the fastener, slightly past the bottom of the head. Try to knock the head off. If it doesn’t come off, go one step up on the drill bit size and drill gently to the depth of the bottom of the head. What you’re trying to do is drill the head off without disturbing what’s left. Once you have the head off of both screws, remove the part and then grab what remains of the screw with a pair of vise grips and unscrew it.

It takes longer to write about it than to actually do it.

[pwd72s]

Youtube is full of how to videos...here's one.

[pwd72s]

Another option...but really $pendy vampliers screw extraction pliers

[DWBOX2000]

I started drilling the bolts out and they just popped through into the wheel well. Looks like there is nothing to screw into but they were somehow anchored somehow from the back. Just holes in sheet metal to attach. I was thinking nut and bolt but really don’t want to take plastic wheel well liner off. I just know it will cause other issues. Any suggestions on attaching the lid? Thanks

[herr_oberst]

I'd be getting out the riv-nuts and the riv-nut installer about now.

[masraum]

Originally Posted by DWBOX2000

I started drilling the bolts out and they just popped through into the wheel well. Looks like there is nothing to screw into but they were somehow anchored somehow from the back. Just holes in sheet metal to attach. I was thinking nut and bolt but really don’t want to take plastic wheel well liner off. I just know it will cause other issues. Any suggestions on attaching the lid? Thanks

My guess based on your description and issues is that they were riveted on. That's why you couldn't get anything to "bite" in the "bolts" because they weren't bolts so their was nothing to bite.

You could try to find a pop rivet gun and rivets that are big enough, but how big are those holes? They look pretty big.
You could try to get to the back of the area through the wheel well and then use bolts and lock-nuts. You could also use short sheet metal screws.

[masraum]

Originally Posted by herr_oberst

I'd be getting out the riv-nuts and the riv-nut installer about now.

I'm not sure what a riv-nut is (I'll be hitting google) but that sounds like the right answer to me.

[HobieMarty]

What about installing a bolt that is slightly larger in diameter so that it just screws into the hole? Used some red loc-tite on them and they will never back out. Lol.

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[javadog]

I’dbe heading down to the dealer and buying two more of whatever was in there in the first place.

[masraum]

Rivnut looks like a good way to go if you can find some in the right size and style.

https://www.rivetnutusa.com/rivnut-rivet-nut/

[DWBOX2000]

I went to hardware store and got self taping screws. I put a little lock tite on and it seems fine. That’s all.

[MBAtarga]

For future reference - no special tool is needed. In the case of onesey - twosey I'd not bother with purchasing the tool.

https://www.blindrivetsupply.com/How-to-Install-Rivet-Nuts-Without-a-Tool_b_12.html