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Help removing stripped/sheared bolts

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Old 04-05-2013, 10:10 AM   #1
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Help removing stripped/sheared bolts

I was removing the bed rail bolts to install my new tonneau cover, but I had these 3 bad bolts :

This one still has the head on, but won't turn. I tried to score a line, but it still won't turn. The bolt itself feels really soft and the material keeps stripping. Unfortunately, I went out and bought a bolt extractor from Harbor Freight (or easyout/Grabit) but the extractor head broke off inside the bolt.


This one the head sheared off, leaving just the bolt stem in the rivet nut (?) I thought maybe the extractor head broke off the other one because it was a cheapy from Harbor Freight, so I went down to ACE and bought the Grabit (a lot more expensive), but the extractor head broke off in the stem too.



This one is from the tool box. The head sheared off, but I can see the back of the bolt stem. I tried turning it with a vise grip, but it won't turn. Having stripped the other bolts, I didn't want to do any more damage to it by shearing off the rear end too.



Any suggestions would be awesome!

Thanks
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Old 04-05-2013, 10:15 AM   #2
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Die grinder? The first two pictures arent showing up.
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Old 04-05-2013, 10:18 AM   #3
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maxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shedmaxamillion2345 is one of the sharper tools in the shed
 
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Grind the head of the bolt off if it has a nut and not in threaded blind hole.

Grind the head to a useable shape

Drill and use extractor, drill and drill and drill
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Old 04-05-2013, 10:38 AM   #4
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I guess I can probably grind off the rivet nut... maybe put a new rivet nut in? Any idea what size it is? I know the torx head is a T-30
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Old 04-05-2013, 10:52 AM   #5
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After trying to remove the bolt by center punch. drilling, and easy-out. I drilled out the nut on the bed rail and used a longer same diameter bolt and put a lock washer and nut on the inside of the bed rail. I used stainless allen head bolts. I also replaced all bed rail bolts with same.
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Old 04-05-2013, 11:56 AM   #6
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was hoping to retain the original nut if possible... but looks like I may have to drill it out like you did. thanks
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Old 04-06-2013, 08:25 PM   #7
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Updated the links for the first 2 pics. Hopefull they show up now.
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Old 04-07-2013, 12:36 AM   #8
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Cutting wheel.
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