Stripped Door Hinge Bolts

[MajorUrsus]

So I’m trying to install some accessories on the door hinge but I can’t get the damn things to break and I’m very close to stripping one of them.

I’ve done the heat gun to try to warm it up. I’ve also tried a breaker bar and even a 24volt impact impact wrench. The damn things won’t break!

Any thoughts or ideas? And how do I handle the stripped bolt head?

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[arosen1997]

Hmmm, normally I'd suggest a manual impact driver, but I'm unsure if that'd dent the door.

 

[MajorUrsus]

Hmmm, normally I'd suggest a manual impact driver, but I'm unsure if that'd dent the door.

Yeah, I was surprised that the impact wrench did absolutely nothing, even with heat. And I think it actually bent the splines on one of my torx bits. My biggest “fear” really is snapping the head off. Really don’t want to drill a tap.

 

[Sunnysideup]

My Dad was having a similar problem with his jk... and it looked about like what you are facing. I got the tighest torx bit into the bolt heads...leaned into it with an extention and used a hand ratchet to slightly move it until it would spin. He only had one set get messed up- but he started with an impact wrench and I did the rest with a ratchet- and it worked. We had to tap out one of the two that stripped. I am surprized heat didn't help you out too...

 

[DFlannery31]

I had the same issue with two of my bolts. I’m just going to go ahead and tell you the news you don’t want to hear…You will probably end up having to drill them out. That was the only solution I had left. Start small and work your way up until the head pops loose. Then you’ll be able to swing the hinge open and unscrew the rest. Just take your time. This is something you definitely don’t want to rush and make an annoying problem an expensive problem.

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