Rusty bolt + Unable to remove bumper - Help!

[KillerHERTZ]

Yesterday afternoon I attempted to remove my front bumper, 3 of the bolts unscrewed fine, the fourth (drivers side bottom) requried a huge amount of force to get it turning.

Once it started turning it wouldnt stop, it appears I have broken the welded on 'cap' which is the top of the bolt, off of the chassis - see Detailed drawning below:

My problem is that the nut and bolt keep turning through the hole in the chassis, this means the bumper is stuck on the car

The easy solution would be to hold onto the cap with some pliers and unscrew the nut off the bolt, except there is virtually no room at all due to the raditor and I cannot even get my hand behind it

Any idea's? before I get my garage to saw it off?!!

 

[Howard]

Can you not feed a pair of mole grips up there and lock them on ?

 

[KillerHERTZ]

No I have attemped to get some plyers behide it, but theirs barely enough room to fit my fingers...

 

[Sp!ke]

Isn't this what angle grinders are for?

Job done in a couple of minutes, then replace the nut an bolt.

On the plus side, if you dont own an angle grinder, now you have an excuse to buy one

 

[KillerHERTZ]

Isn't this what angle grinders are for?

Job done in a couple of minutes, then replace the nut an bolt.

On the plus side, if you dont own an angle grinder, now you have an excuse to buy one

The trouble is, the access to the bolt is tiny, its between the Left hand fog light and the numberplate, that tiny gap is only 3" high at most, id say it was impossible to fit one in?

 

[LastMinute]

Any chance of getting a hacksaw blade in there to cut through the bolt?

 

[KillerHERTZ]

Any chance of getting a hacksaw blade in there to cut through the bolt?

Whoops, sorry I had forgot to add that I have, I had to remove the saw from the blade and I tryed for 15mins to - made virtually no mark + my finger is cut to pieces as a result.

I could saw through the bumper clamp itself, apart from that I have no idea how I/my garage are going to free it.

 

[LastMinute]

How about a Dremel (or similar) with a grinding or cutting attachment?

 

[KillerHERTZ]

Good idea!, but again space is an issue + I would have to get the blade in this gap:

Are Dremels strong enough to cut through hardened bolts?

 

[LastMinute]

I used to have a cheapo DIY store own-brand "Dremel" and it came with a flexible shaft attachment that was maybe 40cm long and 1.5cm across. So the size of the motor unit wouldn't matter - I imagine you'd be able to get a cutting wheel (maybe 3cm diameter) through that gap?

With the right bit (there are millions), I would expect a Dremel to be able to cut and/or grind a bolt. It might not be quick, mind you...

 

[grober]

Try using several new mini hacksaw blades with a leather/gardening glove to protect your hand. You will have to lock the bolt to stop it from rotating somehow otherwise you won't cut thro the bolt but merely rotate it. Only other thing I can think of is to "slot" the end of the bolt so you can stop it rotating with a screwdriver or file a couple of "flats" on the bolt so you can turn it with a open ended spanner/vice grips while locking the nut with a ring spanner or vice versa. Difficult to see what the access is like so feel free to ignore this if it makes no sense.

 

[Howard]

Karl , where you are holding that nut in the picture , can you get a pair of bolt cutters on it , and just chop away until the bolt / nut comes to pieces ?

A pair with nice long handles , will chop through the nut and bolt together no worries

By the way , you've left your foglights on in the picture

 

[Dieselman]

The nut and bolt won't be hardened steel so a hacksaw blade should do it. Bind it with masking tape for comfort....(you pansy)..

Alternatively use a nut splitter to split the nut off the bolt.

 

[grober]

The nut and bolt won't be hardened steel so a hacksaw blade should do it. Bind it with masking tape for comfort....(you pansy)..

Alternatively use a nut splitter to split the nut off the bolt.

Something like this http://www.tooled-up.com/Product.asp?PID=26332

 

[Dec]

Is there a prize, for whoever gets it right?

Dec

 

[Inkyskin]

This might seem crude, but is there enough room for a chisel/hammer approach?

 

[hosejockey]

Reckon nut splitter is the best option ! Had to do a fairly simular job myself ,nut splitter done the job .

 

[KillerHERTZ]

By the way , you've left your foglights on in the picture

Just for you

This might seem crude, but is there enough room for a chisel/hammer approach?

No chance (without damaging the bumper)


Nut splitter seems a good idea - how exactly does that work?

From the looks of it, you slowly turn the bottom of the handle and the pin is forced cracking the nut?

 

[moakesr]

Nut splitter seems a good idea - how exactly does that work?

From the looks of it, you slowly turn the buttom of the handle and the pin is forced cracking the nut?

Exactly, it's like a cold chisel, the steel of the pin is hardened and will cut through the nut with ease.

 

[gurpz]

I know its off topic but whats the reason of removing the bumper in the first place ?