Been chipping away at numerous small jobs and yet nothing is done. Some headache or missing part at every stop.
Everytime, I try to remove stock bolts on this Jeep is when I am cursing like a sailor. It isn't a rust bucket, it is fairly clean. I use a MAP torch for at least 2 mins each bolt or more. Typically spray both sides if accessible with PB Blaster days before, and yet I continually can't remove 1 out of 4 bolts to save my life. This is with a manual impact and/or a breaker bar.
Trying to install an OR-FAB tire carrier for the second time (last time gave up and sold it because I couldn't remove 7 bolts, widdled that down to 3). I am fed up with the swing out Metalcloak tire carrier, it is an utter POS imo. It bounces with the wind and squeaks to drive you insane. It also sticks out too far and doesn't swing easily. 3 strikes and you are out.
Here is my attempt to back out the 3/16" bolts from the lower hinge, in order to install the spacers. I liberally coated the bolts in PB blaster days before trying to remove, and after about 1.5 mins each bolt with a MAP torch, enough to scorch some of the surrounding paint. Use valve lapping paste that I saw on YT as a trick for more grip. Pounded the bit in there with a dead mallet. Tried the whack-a-mole impact wrench first. No go. Tried the Bosch impact wrench, no go. Then tried the breaker bar with a 1/2-3/8 reducer. No go, ended up rounding both bolts.
Now what?
I have many of such cases. There is no visible rust but this is a common occurrence.
The roll bar bolt picture is from last time after trying the MAP torch for 10 mins on the bolt, over multiple sessions spread out over more than a week. Lots and lots of PB Blaster. Eventually used a dremel to cut the sides off the bolt since I stripped the hell out of the insert and wanted leverage. Vice grips and leverage bar and still no go. Ideas?
I don't have access to a welder or I'd try to weld on a nut and try that, but I sheared one bolt off trying to remove a bumper. So even that I am skeptical of.
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