I have begun the prep process for painting. I wanted to remove the windshield from the jeep to sandblast and paint separately. When I tried to remove the bolts with the star bit, most of them stripped out. Is there an easier way to do this? Will I have to drill them out now? Thanks for the advice.
once they're stripped (too easy to do) you've only got a few options
1- weld a nut to the head so you can use a standard socket on it (probably best method to try if you have access to a welder)
2- with a cutoff wheel, cut a slot in the head so you can try and use a flat screwdriver (but if it's that stuck, that slot will probably strip out too... then back to #1)
3- drill it out as large as you can and use an ez-out
[FONT="Comic Sans MS"][COLOR="Blue"]Sean B. - Schenectady, NY - 95 YJ, 350/700r4/NP241, JB Shorty SYE, 8.8 rear, 2" BDS, 1" homebrew shackles, Daystar 1" BL, TJ flares, 35x12.50 General Grabber AT2 on 15x10 Bart D-Truckers, Polyshield polycarbonate windshield, HD over/under crossover steering
[/COLOR] [COLOR="Red"]swap/build thread: [url]http://www.jeepforum.com/forum/f22/after-almost-4-years-finally-my-own-build-swap-thread-1542284/[/url][/COLOR][/FONT]
I have already done some primering around it so I hate to weld. But I may have to. That sounds like the most dependable solution. I will definitely go with some stainless bolts when I put it back together.
Are you removing the entire hinge, or just unbolting the top bolts? If you're taking off the bottom half of the hinge, just drill the rubber-ducker out. There are nuts on the other side that just spin. If you do a search for "YJ mirror relocation bracket install" you'll see what I'm referring to. You pretty much have to take the dash off to get to them.
Not worth struggling with the old ones. In the process of drilling them out, it should pop off the nut on the other side if it's not already broken loose.
When you reinstall, you just add a regular nut to the backside. (You can put a wrench on when you tighten or just tack weld/adhesive it to prevent needing to take off the dash next time you want to pull that bolt.)
EDIT: I'm only referring to the bottom section of hinge. I don't know about the backside of the upper bolts. Someone more knowledgeable will have to pipe in about that.