Stripped/stuck bed rail bolt

All,

I'm at a loss of options here.

In trying to drop the factory deck rail system to install my tonneau cover, the bolt closest to the drivers side cab stripped. It refuses to move.

Tried so far:
PB Blaster
cutting notch, flathead + vise grips
drilling hole and using easy-out. The easy-out snapped off in the hole.

So here I am defeated.

Has anyone else managed to screw up this terribly on such an easy project, and have any ideas on how to get this sucker out finally?

 

Did the bolt head snap off? Could you weld a nut to it and remove?

 

Post a pic of it to see what we are working with.

 

Pics

 

How about drilling it out?

 

Drill a hole and use an EasyOut. They have got me out of many jams when a bolt has snapped. Backing out the bolt with the Easyout bit is easy and use's a reverse thread so it tightens as you try to back out the bolt.

 

Drill out the center w a drill big slightly bigger than the threads. The head will eventually separate them you can use vise grips once the rail is out.

 

Do you see the thing in the middle? That's my easy-out that snapped

 

EasyOuts work well. I'd drill the hole for the easy out then apply heat to the bolt then immediately back the bolt out. Use a socket extension by placing the tip against the bolt and use a torch on the extension to transfer the heat to the bolt and prevent the torch from damaging your truck. Good luck.

Oops. Just saw your last post. Bummer!

 

I have an appointment tomorrow at the dealership for them to fix some window weather stripping that started coming loose. May just bite the bullet and have them get this sucker out. I'm really at my wit's end with this.

 

Duh
Damn that sucks
Actually the try and weld a nut (your nuts are fried) on isn’t a bad idea
Good luck keep us posted

 

I did this same thing a few weeks ago(different bolt and location) but can you use tweezers or needle nose pliers and work that broken easy out, out. Looks like you used to small of an easy out. If this doesn't work then try drilling it and and slowly stepping up to a larger bit till you just slightly smaller than the threads. You'll be able to work out the remaining bolt afterwards

 

I'd also use left hand drill bits(I think that's what they are called).

 

You can still get that out. You need a fat flat top extractor like this.

 

Grind the rest of the head off and get the rail out of the way so you have some room to work on it.

 

Good news: Dealership got the bolt out and no charge.

Looks like they took a grinder to it , the rail lips took a little damage but I don't care.

 

That was nice of them!

I have had inconsistent luck with easy-outs. My best approach is to just carefully center-drill until only the threads are left, and then re-tap or pick the thread material out. If that fails, drill it out to the next size and re-tap.