Sheared screws on my Prinsu Rack

So I apparently overtightened a couple of the screws on the crossbars on my Prinsu rack. Or they seamed to rust in place, or a combo of both. When I went to remove the screws, the bolt sheared off. Any good ideas, tips, tricks to get the threaded part out of the rail??

 

When you say screws, we talking the self threading type or a threaded screw going into a threaded hole? If threaded, it’ll be easier to extract. If it’s a tiny diameter, tricky.

Saturate with plenty of wd40 or on pb blaster to help with the rust.

 

This is the problem with dissimilar metals especially aluminum and stainless steel. The aluminum most likely expanded due to corrosion and is gonna be a SOB to get out. If it was me I would undo all the screws I could. Spread the sides of the Prinsu rack out and remove the cross bar. Heat and beat with a hammer to loosen bolts and hopefully there is enough room to get vise grips on the broken off heads threads.

Then put Cadium Plated Hardware back in. https://www.mcmaster.com/bolts/fini...y-navy-medium-strength-steel-hex-head-screws/

 

So no the screws are smaller, not tiny tho. I was thinking of removing the rail, the soaking with PB. Then, if there is anything sticking out past flush, try vice grips. If not, use a Dremel cutting wheel to make a slot for a flat head screwdriver, and try carefully unscrewing.

 

Not sure if you have one if these kits but it has saved my a$$ many times

https://www.lowes.com/pd/SpeedOut-8-1-8-in-Double-Ended-Screw-Extractor/1000170531

It’s surprising how well it works. The smallest bit may be small enough for your issue.

 

Second the speed out. Lots of different sizes available. Soak in PB blaster or Kroil’s first over a couple days.

 

Third, this type of extractor works well on smaller screws. You might need to clean the penetrant off where the extractor contacts the screw to get it to grab.

There’s a tool called vampliers. They’re not cheap but work very well, instead of vice grips.

 

I just did this a few weeks ago. Seems like those bolts are pretty brittle! I removed the crossbar from the rail and was able to get some vice grips on what little thread was left. I was lucky and I was able to get them out without too much fuss. Good luck!

 

Just figured I'd pop into this thread since I'm having the same problem. Bought a nearly new Prinsu from an acquaintance and he put the cross bars in non-standard positions. When I went to move them I snapped the heads off 5-10 of the bolts on 3 different cross bars. I managed to get one, maybe two of the snapped screws out of the cross bars but the others are stuck. Been soaking them in PB blaster for weeks in the garage.

Tried that SpeedOut kit - what a waste of money. I'd used similar years with ZERO luck but went out and bought a kit based on the recommendations in this thread. Figured I maybe just had a bad experience or had a bad brand back then. Nope. These are just garbage. Maybe they work for non-seized screws that just have mangled heads but I don't see them working at all for anything where the bolt is actually seized or broken. Waste of money if you ask me.

Looks like I'll just be replacing the cross bars as I don't think there's going to be any way to get these out I may try drilling them out fully and seeing if I can save the threads with a tap but it's pretty unlikely to work I think. Gotta order an SAE tap set though as I only have metric. Speaking of which, I really hate when companies use SAE hardware for stuff like this, everything should be metric! lol

 

I would use a small enough drill bit to remove enough of the screw to where you can break the rest of it up without damaging the threads in the crossbar.

 

I've drilled two out this way and so far, it looks like this isn't going to work. First off, it's super hard to get your hold DEAD center of the screw. Second, the metals are seized/corroded so even after drilling out the center of the screw the remaining screw material does not want to dislodge from the crossbar.

 

$16 COMOWARE Left Hand Drill Bit Set, 13 Piece | M2 HSS with Titanium Nitride Coating | SAE (1/16" - 1/4")

https://www.amazon.com/dp/B07QKS4Z71?_encoding=UTF8

 

Yup, tried that too. The drill just drills the center of the screw out like a regular right hand drill rather than catching and actually loosening the screw.

 

Just went through this. I drilled the snapped bolts and re-tapped with 1/4-20. Got lucky without trashing it up but it took a while. Broke an Irwin spiral extractor trying to extract them out so I moved to drilling it completely. Might be worth it to just replace the bars.

 

If you bought it new they are cover for as long as you are the original owner, I just had 6 new ones sent to me last month . They did say use purple thread lock to keep water out and keep the screws from rusting

 

I did actually buy replacements already. TNutz was having a sale so I picked some up assuming I likely wouldn’t be able to repair all of mine. But, figured I’d at least try to fix em. That way I’d have extras or material to make something else perhaps.

I’m gonna order a tap but so far I don’t think my drilling ability is up to par to make it work. So far I haven’t been able to get dead center on the old bolt.

I now understand why they say to use thread locker. I wish the instructions stated it’s purpose. I bought mine used and the OP didn’t use any. If I had bought new, I likely wouldn’t have used any either - making the assumption it was overkill for idiots who don’t know how to tighten down a bolt. They should state it’s for corrosion protection and that without it the bolts WILL 100% fuse themselves to the crossbars even after only a short time in the most delicate of conditions.

 

If you cannot get it out, you can buy individual rails from Prinsu to replace that one rail. Or, you might ask customer support sbout this issue and they may surprise you with a new rail.

 

was about to say that or you can even buy them online via a few different places for about $20. https://www.tnutz.com/product/ex-10...tted-aluminum-extrusion-for-prinsu-roof-rack/

they also supposedly have a lifetime warranty from prinsu/cbi so you would always try hitting them up.

 

They sent you 6 new crossbars for free?!

 

Yes sir and all new hardware, again you have to be the original owner with proof of purchase.