I need to remove Rusty and Broken Bed Screws to install Tonneau Cover

I am trying to install a BAK Revolver x4ts Tonneau cover in my 2012 Tacoma. I have to remove the bed tracks. The problem I face is many are so rusted, that even with PB Blaster the heads just spin off the screws and break off inside the hole. I need the threaded holes for the mounting clamps. I am left with broken screws inside the bed. I also have 2 on the head rail that just spin. there is some kind of retainer behind them that I cannot reach, except with my finger. I have tried the Speed Out bits to remove stripped screws and it worked on some. But what I have left is the broken screw with no head. Many broke in the hole so
i can't cut a slit and use a flathead.

 

Screw out bits are tough work. They break or just never end up gripping the broken fastener. If screw outs fail, drill and tap a new threaded hole right through the shank of the old fastener. I’m the same thread size. It is basically fused to the old threads anyways, like a solid hunk of metal. You can get 1 bit and matching die, plus a T-bar to turn the die. The first time I tried it was on my truck and it was not overly difficult. The new threads hole is weaker than the original, so when you do put the fastener in, torque to about 2/3 of spec, and some blue threadlocker

 

Great advice, thank you. I ended up doing something similar. I drilled it out and installed a Helicoil. It seems to work fine. By the way the screw out bit sucked. After one screw it seemed to dull. It wouldn’t drill on the drill side, and wouldn’t grab on the other. I did manage one screw with it first.

 

I replaced my screws with stainless