broken door hinge bolts

[Mikes 73 Bronco]

Got new door hinges, Broke 3 bolts off on the door pillar now what? Broke easy out trying to get them out... Is it front door pillar time?

 

[DirtDonk]

Good question Mike! Not sure if it's total replacement time, but you'll get lots of help here, since a LOT of members here have been-there-done-that before you.
"Common Bronco issue" #37 in fact. It's a long list...

Although you'll likely get some quick answers, try the search function too. I think there was another discussion (or two?) about this just a short time ago. You might find some more answers there first.

Good luck.
Oh, and welcome too, by the way. In case you haven't already had a warm welcome in your 5 posts so far.

Paul

 

[Mikes 73 Bronco]

thanks man

 

[Vintage Steel]

Left handed drill bits to start with.
sometimes you can heat it with a torch ( not the best on your paint!) and spray PB blaster or WD40 on it and it will come out.
If you cant or don't want to do that, my friend had a similar situation a few years back. He found "the bolt doctor" in the yellow pages this guy came out and for $25 drilled a steel stud out of an aluminum 22RE block Retapped the treads PERFECTLY and Tracy put his Toyota back together

Check the yellow pages

 

[jlong1974]

I had the same problem. I was able to get a hold of the broken bolts with a pair of vise grips. I then heated the plate with a torch and melted a little paraffin wax on the broken bolt. The wax draws itself into the thread and helps to lubricate. I was able to get four out this way and only had to drill one out.

 

[DirtDonk]

Cool jlong. Sounds like a lot of work, but worth it.
Just curious, did you have to grab the threads from the backside (fenderwell) or was there enough left of the broken bolt up front to grab?

Paul

 

[jlong1974]

The four looked to have been broken at or near the bolt head, and the one I drilled out was flush with the threaded plate. They were a gift left by the PO. I was able to get them all from the front.

When I bought my bronco I only had three bolts holding the drivers side door on, one in the top hinge and two in the bottom. Those three came out without issue. With the doors off I was then able to thread shorter bolts with an area washer into the good holes and tighten the floating plate down so it wouldn't move around while I worked on the broken bolts. Once the broken bolts were out, I ran a tap in all the holes to clean up the threads.

 

[Mikes 73 Bronco]

Didnt try it from the back. Do you have to cut a hole to get to it?? And they broke off flush.

 

[ransil]

I had the same problem. I cut the kick panel for access then removed the plates. The perches they sit on also needed rebuilt.
I still could not get them out after welding a dozen nuts to them and soaking for a week.
Best solution is to get new plates, not sure if you can buy them from a vendor I had mine made.

 

[brut67]

I agree with some of the other posts....If you can grab the bolt with vice grips, heat and cool the broken bolt 3 or 4 times, add WD40 or wax, and the bolt will come rigth out.

 

[Madgyver]

This is how you do it...

http://classicbroncos.com/forums/showthread.php?t=117541&highlight=plasma+cutter

Welcome to the site.
I am magyver

 

[Bronco_69]

here is how i have done it several times.

get a 7/16" nut and center it over the broke bolt. use a mig welder and weld it. fill the center first and weld out. let it cool and then remove it normally. works like a charm.

 

[Mikes 73 Bronco]

Hey guys thanks for the help!! got them out the back. Life is almost good again.