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post #1 of (permalink) Old 08-17-2001, 03:37 PM Thread Starter
 
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Those stubborn hinge bolts

I just finished very heavy battle with those button_head bolts - I won [img]/wwwthreads_images/icons/laugh.gif[/img]. I've managed to remove ALL of them (including the rear gate) breaking off only two of them, but a quick drilling and Dremel'ing <sp?> fix that too.

Then I've chopped the top portion of the front door hinges in order to be able to take them off (doors) quickly and replace with my half-doors which I've made last week. That along with the snap-in door limiting belts worked marvelously :-), so now I can enjoy ride with a really big side view [img]/wwwthreads_images/icons/smile.gif[/img][img]/wwwthreads_images/icons/smile.gif[/img][img]/wwwthreads_images/icons/smile.gif[/img][img]/wwwthreads_images/icons/smile.gif[/img][img]/wwwthreads_images/icons/smile.gif[/img], oh yeah baby.

FYI, from the practical point: DON'T even think of taking on those bolts without a really good quality #3 Philips bit that fits in your ratchet handle. Then park the vehicle parallel to a wall or something like that in such a distance that you can get in between and put a REALLY big pressure on the ratchet with your body while trying to rotate the handle. In 99% of cases after a loud SNAP!!! the bolt will come loose without shredding itself to metal dust.

I replaced them bolts with a descent stainless steel hardware - here's the number:
SS Button Head M8x20 bolt, SPAENAUR# 373-326

And here's the OEM Suzuki# if someone needs it: 09125-08015 (three times more $$ than above.....)

Hope it helps

-marker
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post #2 of (permalink) Old 08-17-2001, 04:18 PM
mike shannon
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Re: Those stubborn hinge bolts

buy your #3 phillips head from sears and use a impact driver. i have done 5 sets and never messed one up yet. i have found out that it seems to work better with a 20 oz. hammer than a two lb. sledge. my 2 cents later mike

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post #3 of (permalink) Old 08-17-2001, 04:25 PM Thread Starter
 
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Re: Those stubborn hinge bolts

I've tried the impact driver as well....I'm sure it works OK on the rust-free vehicles, but on mine (hmmm...slightly rusted :-) wouldn't move a thing and I was afraid to dent the somewhat delicate [img]/wwwthreads_images/icons/smile.gif[/img] Suzuki body panels.
But again, whatever works.

-marker
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post #4 of (permalink) Old 08-17-2001, 04:47 PM
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Re: Those stubborn hinge bolts

If you heat the screws with a small micro torch (butane), they come out without any real gruntage. I've found that the locking compound Suzuki uses softens with the heat. Rust didn't seem too much of a problem for me.
Certainly, if one uses the torch method, one should be really carefull not to blister surrounding paint or worse.

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post #5 of (permalink) Old 08-17-2001, 04:56 PM
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Re: Those stubborn hinge bolts

Butane torch? Sure? I keep those around to light my crack pipe. LOL. Just playing. Anyway I spent some years removing screws and can tell you that impact works great with the right size tip. Drill and easy out is okay. But the beat thing I have found is a Cheater bar or Lever wrench. I can't explain but if you ever worked on Aircraft in the service you know what I am talking about. I have also found that if you pre soak them with penitrant it works will also but eliminates any use of the torch method witch work for any bolt with loctite on it. .02

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post #6 of (permalink) Old 08-17-2001, 04:56 PM
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Re: Those stubborn hinge bolts

Butane torch? Sure? I keep those around to light my crack pipe. LOL. Just playing. Anyway I spent some years removing screws and can tell you that impact works great with the right size tip. Drill and easy out is okay. But the beat thing I have found is a Cheater bar or Lever wrench. I can't explain but if you ever worked on Aircraft in the service you know what I am talking about. I have also found that if you pre soak them with penitrant it works will also but eliminates any use of the torch method witch work for any bolt with loctite on it. .02

I Work to Wheel, because I wheel, I work.
http://www.geocities.com/zuk_tonka/zuk.html
post #7 of (permalink) Old 08-17-2001, 06:43 PM
 
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Re: Those stubborn hinge bolts

I know exactly what bar you are talking about. That's one thing I wish I had from the toolboxes I used to checkout for my daily walk onto the flight line.

When I was attemptin to get those bolts out, I tried finding one to no avail.


Mark
1986 Suzuki Samurai soft-top
1999 Toyota Tacoma
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post #8 of (permalink) Old 08-17-2001, 06:47 PM
 
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Re: Those stubborn hinge bolts

My humble opinion --- In this order: penetrating oil, bang bang (hammer kisses), 24 hrs, #3 philips on an impact hammer with 2 lb sledge, Craftsman stubby #3 philips in one hand while using vice grips round the outside of the screwhead, dremel a good flat notch and use a flathead with a cheater.

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post #9 of (permalink) Old 08-17-2001, 07:21 PM
 
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Re: Those stubborn hinge bolts

Give me a nice sharp cold chisel and a nice sice ball peen hammer, and I will have all of them out and be drinking a beer while your still dripping sweat on the first half dozen! I tried all the methods mentioned, and I will stick to my chisel. As far as the SS hardware, would be interested to know what the cost was, we sale a 116 piece all SS set to replace both sizes of the pesky screws for $21.95. Thats 58 bolts and 58 washers.

TGT - NCO

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post #10 of (permalink) Old 08-17-2001, 08:59 PM
 
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Re: Those stubborn hinge bolts

I agree with Tim, the chisel is the easiest way to remove them.Ive tried an impact driver, and it didnt work. I also like using a #3 phillips bit on a 3/8" air powered impact wrench, this way you can put lots of force on the bolt so it wont strip it, using 2 hands and thats all you have to do, no turning. 1/2" impacts are too powerful and just strip the head right away.

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