i have a passenger dr that i need to replace with a spare door i have but have noticed 2 of the bolts on the lower hinge r broken off how do i remove these ...help please
Grind them flat, if you can. Take a punch and punch a dimple in the center of the bolt. Drill it out about half or 3/4 as big as the bolt minus threads, the actual body of the bolt. Go to the hardware store and buy "EZ Outs" which look kind of like a dull drill, but are cut left-handed and tapered. When you start to turn them into the top of the hole you drilled in the bolt, they will get tighter until they grab the bolt from the inside. Pull them out. It helps if you put wd40/pb blaster/etc on them now in case they are rusted in there really good.
Also, if you can get all the other bolts free, remove the door and there just might be enough of the broken bolts exposed that you can maybe get on them with vice grips and get them out.
Cut a slot with a dremel and use a flat head screwdriver...or turn it out with a hammer and chisel...get it hot and touch a candle to it, the wax will lube the threads
A better way is to weld a nut over the broken bolt, filling the nut with weld. Just as it turns grey (from white to orange, then grey) unscrew it with a wrench. Works EVERY time. Guaranteed.
I 2nd the nut filled with weld, it does work and heats up the bolt and sort of breaks the bolt free with the heat at the same time, heres a video on how to do it http://www.ehow.com/video_2327766_removing-broken-stud-mig-welding.html
