Recently stripped a Favorit of some bits. I found that a good few bolts snapped off on the bodywork, and the screws on the rear fogs + reverse light lenses are rusted and also the side repeater covers.

I am concerned that on my car I will have difficulty removing the screws to replace bulbs when needed, and also that if I attempt to replace the screws now I will cause more problems than I cure.

I also found that on the mirrors the bottom screw is guaranteed to be very tight and cam out. I have even tried using an impact driver with no luck, and also attempting to drill off the head didn't seem to work as the drilling left the top bit of the head still on (guess needed a bigger drill bit maybe).

How do you deal with these types of problems? Is there solutions almost guaranteed to work every time?

In all honesty every screw/nut/bolt will be different, previously i have drilled off heads, chased bolts out, stress relieved by cutting at key points, used cam boxes, easyouts, drilled out completley and helicoiled, soaked in looseoil, used heat and had bits spark eroded.

Best thing to do is hold a few different techniques in your back pocket and apply them to the situation as and when needed.

Preventitive measures work well perhaps using copperslip on any threads you are putting in, but take care it isnt suitable for every bolt on the motor.

HTH

D

I've heard- soak well with WD-40 or better, whatever, try gently with the right driver, never really force it or it will break.

Use a smoke wrench (oxy torch) to heat up a couple of times, then whack the head with a hammer on the driver to shock it. If broken off with a nub sticking out, you can place a nut on the nub and weld into the centre. I've heard that easy-outs expand the stuck fastener and can make it more difficult to remove.

Ultimate must be the heli-coil.

Just remember that even the best of the best struggle with stuck fasteners and keep your cool.....

Good luck

Bas