Hello guys,

Been working on my car today to try and replace my damaged AC condenser. To do this I need to remove the reinforcement bar behind the bumper - this is held on with torx bolts. Two have rounded off There is not enough room to get in with a drill to drill them out. I've tried a nut splitter but the head of the bolt is too thin and round for this to work. Does anyone have any genius ideas that will make my day?

Edited 5 May, 201214 yr by piggoy

What about mole grips?

They are actually Spline drive :p

In similar situations I have simply electric welded either another nut or even a bolt to the damged part, when cold it's a doddle to remove.

Or even try a hammer and short screwdriver or chisel on the outer edge, it's amazing what a few shock jabs will do to loosen it's grip.

DB.

Edited 5 May, 201214 yr by mogwye

dremel and a drill. hasn't failed me.

Hammer and chisel, make a small indent with the chisel then start to chisel the bolt around anti clockwise to loosen it off but this probably wont work if the bolts really tight but if its loose the bolt should start to turn if your carefull

What about mole grips?

They are actually Spline drive :p

Mole grips have also failed - the head is too shallow to get any purchase with anything. Yes I realise it's a spline drive - trying to undo it with a torx bit probably contributed to its demise lol, but it worked fine on all the others without knackering them. Why do they use all these different types of bolt head that you need 50 different tools to undo?? - 5 star torx, 6 star torx, spline drive - it does my nut in - whats wrong with a hex head bolt!!!

Why do they use all these different types of bolt head that you need 50 different tools to undo?? - 5 star torx, 6 star torx, spline drive - it does my nut in - whats wrong with a hex head bolt!!!

Never had a Jap, so can't comment on what they use, but on cars of Germanic descent, for years now ,they've had a passion for fitting stupid fittings. Anyone remember the last mark Cavalier. The water pump lasted for a looong time, so that by the time it had to be changed the allen headed bolts ( Yep -that's right Allen headed bolts, and soft ones at that) had gotten filled up with crud/got corroded. I got one off with moles, the other two sucumbed to a small chissel and a large hammer . My other suggestion would be to try ( if room) to cut a slot for a screwdriver and either try a screwdriver, or use the edge as a point for a small chisel .

Dremel or angle grinder a slot into the top.

I'm only viewing this on my phone so forgive me if I'm miles out but have you actually tried a spline tool as it still appears to have some ridges still visible?

Or the next size up spline or torx drive which you don't mind sacrificing and hammer it in there to get a grip and then undo the bolts. Maybe a good dose of penetrating oil and leaving overnight may help.

Ian

I'm only viewing this on my phone so forgive me if I'm miles out but have you actually tried a spline tool as it still appears to have some ridges still visible?

Well done that man!! A neighbour had the correct spline tool and managed to undo them both for me. That'll teach me for trying to undo them with a torx bit lol. Still, it doesn't make me any happier that VW insist on using these things, i'd rather they used standard bolts and save me the hassle of having to buy more tools.

Cheers everyone for their inputs

Edited 6 May, 201214 yr by piggoy

Buying an M6 to M12 spline set doesn't cost the earth.

Glad to be of help

Well done that man!! A neighbour had the correct spline tool and managed to undo them both for me. That'll teach me for trying to undo them with a torx bit lol. Still, it doesn't make me any happier that VW insist on using these things, i'd rather they used standard bolts and save me the hassle of having to buy more tools.

Cheers everyone for their inputs

Think how I feel!

End up with this....

FBH  -  One size fits all nuts/bolts

Think how I feel!

End up with this....

Think i just done a sex wee lol :-P

Hammer & chisel job.

Ensure new bolts ready for replacements.

Think how I feel!

End up with this....

It's not what you got it's knowing how you use it. LOL