Working on my YJ when I attempted to fold down the windshield. Bent the hinges. Ordered new hinges. Proceeded to round out all but 5 torx bolts. What should I do now? I have created more work for myself than expected. Should I just drill and tap? Has anyone else had this problem?
This is a common problem. You're not alone. drill a pilot hole, 1/16", and then use about 5 drill bits of succesive sizes up to 5/16". Then use a 3/8" bit. The drill will remove the head of the bolt from the shank. No you can either re-tap (not my favorite way) or drive out the shank and put in new bolts and nuts.
Do a couplof things... appply some good old fashioned anti-seize compount to the nuts and bolts. Then ever three to four months drop some light machine oil down in the oil hole in the windshield. Do it like religion before winter sets in and when spring comes. Work the windshield back and forth a little to keep the hinge nice and free.