used a Sawzall to cut off the windshield...Now what?? - Jeep Wrangler Forum

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Old 05-31-2010, 04:01 PM   #1
Join Date: May 2010
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used a Sawzall to cut off the windshield...Now what??

Hello All

My windshiel in my 91 Wrangler was all rusted out at the bottom...even the glass was loose along the bottom

Well I tried to get the windshield hinge bolts to unscrew...used PB blaster for a few weeks...finally after ruining a few Torx bits and a few screw heads, I went at it with the sawzall..the windshield is out EXCEPT for the 2 hinge locations and the 2 areas where the roll bar bolts to the windshield.

I can now see the bolts and nuts etc from the inside....sprayed them all down with PB Blaster....but they are pretty rusty. I am afraid they are seized up forever

any suggestions to get them out short of drilling them out?? What would heat do...I can hit them with a plumbing propane torch

any suggestions would be appreciated


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Old 05-31-2010, 04:10 PM   #2
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First reaction:

After reading your post I would say heat the ones on the rollbar with the plumbing torch. On the hood you'll probably have to drill them and use an ez-out to back them out. If you don't have any experience using ez-outs, beware. They are very very hardened and brittle. You absolutely do not want to side load them because if you break it off in the hole you are pretty much screwed. Is that any help?


PB Blaster is overrated, IMHO. Use a 50/50 mix of ATF and Acetone. Much better and loosening stuck bolts.

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Old 05-31-2010, 04:10 PM   #3
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Drill into the centers of the bolts/heads with actually a small masonary bit. Then use an EZOut or Grabber to back them out.
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Old 05-31-2010, 05:59 PM   #4
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Seeing as you don't have to worry about the windshield anymore, heat the nuts from the inside with an acetylene torch, bolts should come out or if you can get to them all, use a nut splitter.
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Old 05-31-2010, 10:43 PM   #5
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Just drill the heads off the bolts and be done with it.
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Old 06-02-2010, 02:05 PM   #6
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Drill the heads off and grab the protruding part with vice grips.Sometimes just the heat from drilling alone will loosen the bolt.
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Old 06-02-2010, 09:33 PM   #7
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use left handed drill bits if you can find them
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Old 06-02-2010, 10:11 PM   #8
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soak them with brake fluid but be careful the brake fluid will eat the rust but will also eat paint but i would do that it will only take a few minutes for the brake fluid to work
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Old 06-04-2010, 06:05 PM   #9
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Yeah...Drill the heads off. After cutting the freaking windsheild off I would think that drilling would be the least of your worries. I've had to drill about 3 of them. Not fun, but good luck.
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Old 06-07-2010, 08:13 PM   #10
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Thanks all....I have been out of town so I have not had a chance to get at...I just purchased some new drill bits and some easy out to have a couple of options.

I will update when I get to it



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