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Old 06-24-2015, 04:06 PM
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Windshield screw extraction

The things our POs do...

So I guess the PO stripped the screws that mount the roll bar extension the the windshield on the passenger side. No big deal, but they then went a step further and really wanted that windshield down so they drilled the heads off leaving me with a little problem. The only extraction bit I have is 1/4" and I don't even know if i can use it for this. Is my best option spraying it with PB blaster and starting to drill it out with something like 1/8" until it eventually is so little of a screw is comes out? Will I be able to preserve the threads with this?

Might also just try drilling 1/8" through the whole thing and picking up a 1/8" extraction head first. Either way, what is the size torx screw I'll need to replace those?

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Old 06-24-2015, 05:53 PM   #2
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Are they flush with the surface or do they protrude? If there's enough to grab with vise grips, lock them on as tightly as you can and twist them out. If they're flush that means drilling, and you'll really want a complete extractor set for that. IIRC the bolts are 8mm, so a 1/4" drill bit (6.35mm) will open it up to just about the minor diameter. An extractor would most likely be pressing against the threads in the windshield frame by the time you got it tight.

Get one of the kits with 5 different sized drill bit/extractor sets, and start with 1 of the 2 smallest (5/64" & 5/32", IIRC.) Take your time and don't put any side load on those small bits. I wouldn't even bother trying an extractor till you've drilled using the 3rd bit. The heat from drilling may help break things loose. If moderate force doesn't back the bolts out you can either: 1) use bigger bits till you're close to the minor diameter, then use a hammer & sharp center punch to peel the remainder of the bolt threads out of the hole. 2) do #1, but peel just the first couple threads away then carefully use the correct size tap to cut the remainder out. Take your time and back the tap out every time it even starts to feel tight, you don't want to break it. 3) drill the whole thing out and have new nutserts put in.

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Old 06-24-2015, 08:44 PM   #3
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I'm in a similar situation. It's totally not urgent since there is no need to drop the windshield, and I am fully responsible for my situation. I stripped the torx bolts on the windshield / roll bar, and then tried to get them out with extractors, and broke one in the bolt! So drilling is no longer an option.

I cannot weld (and keep thinking if I could, how much better my life would be).

Is the best option to take it to a shop, tell them what's what (meaning, the torx bolts are stripped AND there is a bit of an extractor, carbonized steel I believe, in there) and have them weld nuts onto the bolts to turn them out?

Hope this thread hijack doesn't cause any pain, just saw a similar situation to mine and figured who's looking at this one probably could advise me on mine ....

Good luck nebo, I hope you get them out!

Tim
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Old 06-24-2015, 08:55 PM   #4
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nebo, I ended up drilling mine out. many small holes around each broken bolt. tapping for larger countersunk torx bolts. Drilling the roll bar extensions to fit that larger countersink.

A weekend of ****,****,****. After that I left the windshield up.
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Old 06-24-2015, 09:08 PM   #5
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nebo, I ended up drilling mine out. many small holes around each broken bolt. tapping for larger countersunk torx bolts. Drilling the roll bar extensions to fit that larger countersink.

A weekend of ****,****,****. After that I left the windshield up.
Same here. Drilled out. F this f that. Ended up putting coarse sheet metal screws oversized. Fit like charm with nice 5/8 head
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Old 06-24-2015, 11:37 PM
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nebo, I ended up drilling mine out. many small holes around each broken bolt. tapping for larger countersunk torx bolts. Drilling the roll bar extensions to fit that larger countersink.

A weekend of ****,****,****. After that I left the windshield up.
Hoping it doesn't come to that but with how these things go, a simple extraction probably won't happen. If I could weld I'd just get some crappy drill bits, drill through it, weld the bit in place and reverse it out. I really need to learn to weld....
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Old 06-25-2015, 12:54 AM   #7
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Welding might be difficult because the windshield frame is pretty light sheet metal... with heavier metal behind for the bolts to thread into.
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Old 06-25-2015, 11:27 AM   #8
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If you know someone with a MIG you can simply weld a nut on and it should come right out. That's the easiest way to get them out! The high heat from welding the nut on helps to free it as well.
I know I've been there!!!

Didn't have a photo from the windshield but here's one from the roll bar support on the floor...
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