Pinch Bolt hell - What to do next?

[Spetznaaz]

This is seriously stressing me out.

I'm in the process of trying to replace my front upper control arms. First side was an absolute nightmare, but i managed to get the pinch bolt off after snapping off the bolt head, by tightening a nut the other side, with an oversized nut as a spacer, then cutting a bit off the bolt, adding another oversized nut, tightening until i ran out of thread, then using a spare pinch bolt hammered out the last bit.

The other side however does not want to play ball. Ended up rounding the head of the bolt and couldn't snap it off so had to cut it off (and accidentally cut slightly into the knuckle). Then tried the previous method until i ran out of thread, at which point no amount of hammering would shift it even a fraction of a mm. Got so many little cuts and dings in the knuckle, i really hope it doesn't cause it to fail it's MOT.

Current situation, totally rounded nut:
IMG-20231012-WA0004.jpg

Only car in the household, past the point of driving to a garage and MOT coming up in a few days. I've read about people using a C/G clamp with a nut bit to turn it rather than a handle but can't seem to find them for sale anywhere. This is what i mean:
clamp1.jpg

I've ordered a normal G clamp to tighten a bit of bolt through one end and push the remainder through the other but i don't think i'm going to get the force i need with just a handle to turn:
pinch.jpg

I've ordered this:
712epHobicL._AC_SL1500_.jpg

But i have a feeling that's just going to bend from the pressure and i ordered some cobalt drill bits as a last resort to try and drill it out. Also got some dremmel cutting discs to cut the bolt through the slit in order to hopefully get the end bit out so there is less to drill.

Anyone got any other suggestions to get this damn bolt out? Heating isn't really an option as everyone says don't ever heat aluminium.



Edit - Actually managed to find the clamp with the nut end in a ball joint press kit. Hopefully that will work a lot better:
5109a3AX4XL._AC_.jpg

[Jayz691]

When I did mine, I did them similarly(nut/washer method). But to finish when it ran out of thread, I used an air hammer with a drift bit(ecs), and added a little heat to help.
Hope your supporting the 2 pinch slots. If not, im surprised it didn't snap.
If you got it broke loose, and moving, it should come out with an air hammer fairly easy.

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Attachment 316468

[Spetznaaz]

When it did mine, I did them similarly(nut/washer method). But to finish when it ran out of thread, in used an air hammer with a drift bit(ecs), and added a little heat to help.
Hope your supporting the 2 pinch slots. If not, im sutprised it didn't snap.
If you got it broke loose, and moving, it should come out with an air hammer fairly easy.

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Attachment 316468

Yeah i forgot to mention i put some thin bits of metal i had in the pinch slot on the end i was screwing to support it, probably should have done it in the other one as well but luckily nothing has snapped that i can see. Unfortunately i don't have an air hammer or air compressor and have no where to store one. As i got to the end of the thread it got really hard to turn, so much so that the wrench started slipping off the nut. Not sure what happened but on the other side this didn't happen, the nut bound to the bolt and the bolt started spinning, that's when it hammered out easily. The bolt refused to spin on this one.

I'm really hoping the ball joint press works to push the remainder of the bolt out. Got a feeling the end might be a bit too big for it to work properly but we shall see.

[Audibot]

Air hammer would be my suggestion too.

[Spetznaaz]

Air hammer would be my suggestion too.

I had considered buying a second hand air compressor, and hammer for about £250 but aside from having no where to store a massive compressor, i've seen numerous videos and read numerous forum posts of times an air hammer didn't work. A lot of money for me only to find out it doesn't work. I've spent way more than i should so far on this job, i guess i'll see how my clamp idea works and go from there.

[Audibot]

In addition to some heat, have you tried to see if you can hit the bolt with a punch (stop flaring it out)?

[Spetznaaz]

In addition to some heat, have you tried to see if you can hit the bolt with a punch (stop flaring it out)?

Yeah i've tried a punch to no avail. Haven't used any heat though due to not wanting to heat aluminium. You've just made me think, from trying to whack it out with another same sized bolt, perhaps i have flared the end out inside there and got it even more stuck / potentially damaged the inside of the bolt hole.

[BeefyA4]

I got stuck doing this last week too. Honestly I really wouldn't recommend doing this without an air hammer. I ended up spending $250 on one, trust me cheap ones are useless. You'll probably need it to get the upper ball joints out too.

[Jayz691]

I got stuck doing this last week too. Honestly I really wouldn't recommend doing this without an air hammer. I ended up spending $250 on one, trust me cheap ones are useless. You'll probably need it to get the upper ball joints out too.

Good point. Even after only 2 years, I needed my air hammer to pop the upper arms out..

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[Spetznaaz]

I got stuck doing this last week too. Honestly I really wouldn't recommend doing this without an air hammer. I ended up spending $250 on one, trust me cheap ones are useless. You'll probably need it to get the upper ball joints out too.

I managed to get the other side ball joints out with a ball joint separator and a bit of bolt but it was hard work and i wouldn't be surprised if it doesn't work on this side. Is that $250 just for the air hammer? I am considering getting a compressor, 50L, 14CFM Piston displacement, 9.5CFM FAD, which i think should be just about enough but that's only if i can get it for £100 second hand (waiting on a message back) then i was planning on getting a cheap air hammer and using the pinch bolt drift tool: https://www.amazon.co.uk/Laser-Steer...92&sr=8-6&th=1

Now you've said the cheap ones are useless though... This is all really adding up and the Missus is in my ear saying i'm spending too much. Knowing my luck it won't even work.

[BeefyA4]

Yeah I feel you man. I went with the Ingersoll Rand 123MAX but I've heard harbor freight chief is pretty good bang for your buck though. The cheap ones you might as well disconnect from the air line and use as a hammer. BUT once you have one they make working on so many things a million times easier.

[Theiceman]

Yeah I feel you man. I went with the Ingersoll Rand 123MAX but I've heard harbor freight chief is pretty good bang for your buck though. The cheap ones you might as well disconnect from the air line and use as a hammer. BUT once you have one they make working on so many things a million times easier.

I'm not sure they even have HF in UK

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[Spetznaaz]

Yeah I feel you man. I went with the Ingersoll Rand 123MAX but I've heard harbor freight chief is pretty good bang for your buck though. The cheap ones you might as well disconnect from the air line and use as a hammer. BUT once you have one they make working on so many things a million times easier.

The second hand compressor i wanted has sold and there's nothing else decent about. Can't spend anymore and the ball joint press method failed today. Looked at drilling it out but the angle just wouldn't work, i'd end up having to take the whole knuckle out. Looks like i'm pretty screwed at this point. Might have to get it towed to a garage.

[Theiceman]

you wouldn't be the first guy to have to pull or replace the knuckle that's for sure .

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[Spetznaaz]

Yeah I feel you man. I went with the Ingersoll Rand 123MAX but I've heard harbor freight chief is pretty good bang for your buck though. The cheap ones you might as well disconnect from the air line and use as a hammer. BUT once you have one they make working on so many things a million times easier.

So i've gone and bought an air compressor, 3HP which is the biggest i can run off a normal plug, i hope it's enough. I also got the Ingersoll 123max air hammer but i can't for the life of me work out what hose i need to connect to that and to the air compressor. It say's 1/4" NPT inlet and i think the air compressor is a BSP quick release. All very confusing.

you wouldn't be the first guy to have to pull or replace the knuckle that's for sure .

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I'm really hoping it doesn't come to that but i have a bad feeling it will.

It means having to struggle with the tie rod pinch bolt, lower control arm ball joints (risk of the metal sleeve bit coming out), hub nut, buying all replacement bolts / nuts, then if i can't drill the bolt out i will have to try and find a second hand knuckle, which are hard to find here, or spend £450 on a new one.

Edit -

I just wanted to update this for anyone reading in the future struggling with their pinch bolt. I got myself a 3HP SIP 100L direct drive compressor with a claimed 14CFM piston displacement and 9.5CFM free air delivery. I also purchased a Ingersoll Rand 123MAX air hammer and a Laser steering knuckle pinch bolt drift (https://www.amazon.co.uk/dp/B00M6TSC1M?th=1), used extra flow connectors and a 10mm hose.

The pinch bolt took a LOT of air hammering and i was ready to give up but eventually it moved. Be careful not to get the drift wedge in there like i did - Best to remove the first control arm ball joint as soon as the pinch bolt clears it as this allows you to turn the knuckle for a much better angle.

The compressor was only just enough, it did keep kicking in after every 15 seconds or so of air hammer usage. No heat was ever used.

[heateris]

I ended up buying used knuckles and new wheel bearings when I did my suspension upgrade. F the pinch bolt.


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[Theiceman]

So i've gone and bought an air compressor, 3HP which is the biggest i can run off a normal plug, i hope it's enough. I also got the Ingersoll 123max air hammer but i can't for the life of me work out what hose i need to connect to that and to the air compressor. It say's 1/4" NPT inlet and i think the air compressor is a BSP quick release. All very confusing.



I'm really hoping it doesn't come to that but i have a bad feeling it will.

It means having to struggle with the tie rod pinch bolt, lower control arm ball joints (risk of the metal sleeve bit coming out), hub nut, buying all replacement bolts / nuts, then if i can't drill the bolt out i will have to try and find a second hand knuckle, which are hard to find here, or spend £450 on a new one.

Edit -

I just wanted to update this for anyone reading in the future struggling with their pinch bolt. I got myself a 3HP SIP 100L direct drive compressor with a claimed 14CFM piston displacement and 9.5CFM free air delivery. I also purchased a Ingersoll Rand 123MAX air hammer and a Laser steering knuckle pinch bolt drift (https://www.amazon.co.uk/dp/B00M6TSC1M?th=1), used extra flow connectors and a 10mm hose.

The pinch bolt took a LOT of air hammering and i was ready to give up but eventually it moved. Be careful not to get the drift wedge in there like i did - Best to remove the first control arm ball joint as soon as the pinch bolt clears it as this allows you to turn the knuckle for a much better angle.

The compressor was only just enough, it did keep kicking in after every 15 seconds or so of air hammer usage. No heat was ever used.

congrats .. so you put a drift in , then hammered away on that ? it's the only way I think it could really work .
you get the pinch bolt badge. not many have that badge

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[Jayz691]

So i've gone and bought an air compressor, 3HP which is the biggest i can run off a normal plug, i hope it's enough. I also got the Ingersoll 123max air hammer but i can't for the life of me work out what hose i need to connect to that and to the air compressor. It say's 1/4" NPT inlet and i think the air compressor is a BSP quick release. All very confusing.



I'm really hoping it doesn't come to that but i have a bad feeling it will.

It means having to struggle with the tie rod pinch bolt, lower control arm ball joints (risk of the metal sleeve bit coming out), hub nut, buying all replacement bolts / nuts, then if i can't drill the bolt out i will have to try and find a second hand knuckle, which are hard to find here, or spend £450 on a new one.

Edit -

I just wanted to update this for anyone reading in the future struggling with their pinch bolt. I got myself a 3HP SIP 100L direct drive compressor with a claimed 14CFM piston displacement and 9.5CFM free air delivery. I also purchased a Ingersoll Rand 123MAX air hammer and a Laser steering knuckle pinch bolt drift (https://www.amazon.co.uk/dp/B00M6TSC1M?th=1), used extra flow connectors and a 10mm hose.

The pinch bolt took a LOT of air hammering and i was ready to give up but eventually it moved. Be careful not to get the drift wedge in there like i did - Best to remove the first control arm ball joint as soon as the pinch bolt clears it as this allows you to turn the knuckle for a much better angle.

The compressor was only just enough, it did keep kicking in after every 15 seconds or so of air hammer usage. No heat was ever used.

I had that happen with the drift bit, forgot to mention.. Sorry.

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[Spetznaaz]

congrats .. so you put a drift in , then hammered away on that ? it's the only way I think it could really work .
you get the pinch bolt badge. not many have that badge

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Yeah the tool comes with an air hammer drift attachment thing which gets the bolts so far then you put the other bit of the drift kit inside the hole and use the air hammer with drift attachment on that (there a silver bit with a hole so you can line it all up) and that gets it the rest of the way out. Have to keep cutting off the bolt as it comes out of course or it hits the knuckle.

I had that happen with the drift bit, forgot to mention.. Sorry.

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Lol no worries, the air hammer shook the first ball joint free so that wedged in the drift bit attached to my air hammer. Ended up clamping onto it with locking pliers then hammer it out. What was worse after that was when i used the air hammer drift bit to knock the other ball joint out i ended up going too far and embedding the end in the aluminium in the hole and wedging my air hammer between that and the knuckle. That was an absolute bitch to free and tore my brand new air hammer to pieces lol only cosmetic damage luckily

[86turbodsl]

There's a tool that works great for that pinch bolt, it's sold in the UK.

It is an air hammer bit, with a collar to keep it in the hole, supposedly the hot ticket.

[Spetznaaz]

There's a tool that works great for that pinch bolt, it's sold in the UK.

It is an air hammer bit, with a collar to keep it in the hole, supposedly the hot ticket.

Exactly what i used in the end, worked a treat.

[Theiceman]

someone want to post pics or a link ?

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[Spetznaaz]

someone want to post pics or a link ?

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I did further up. The one i used: https://www.amazon.co.uk/dp/B00M6TSC1M?th=1

Another one sold in the U.S: https://www.ecstuning.com/b-schwaben.../019527sch01a/

[A4Qwattro]

Another trick I use is to twist the head off the pinch bolt with a socket and breaker bar. Then just torque down the nut on the other end to pull it through. The bolt will start spinning once the corrosion is broken free so you can switch to basic hammer and punch after that.

[Jayz691]

There's a tool that works great for that pinch bolt, it's sold in the UK.

It is an air hammer bit, with a collar to keep it in the hole, supposedly the hot ticket.

Thats the ECS drift bit(pinch bolt tool). Its more designed for the b8+, but helps with the b7 too.

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[Jayz691]

Another trick I use is to twist the head off the pinch bolt with a socket and breaker bar. Then just torque down the nut on the other end to pull it through. The bolt will start spinning once the corrosion is broken free so you can switch to basic hammer and punch after that.

That's what he did...

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[Theiceman]

I did further up. The one i used: https://www.amazon.co.uk/dp/B00M6TSC1M?th=1

Another one sold in the U.S: https://www.ecstuning.com/b-schwaben.../019527sch01a/

oh sorry, must have missed it.... some can't be moved with air hammer either.. glad it worked for you..

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[Theiceman]

Another trick I use is to twist the head off the pinch bolt with a socket and breaker bar. Then just torque down the nut on the other end to pull it through. The bolt will start spinning once the corrosion is broken free so you can switch to basic hammer and punch after that.

yeah that's been around 10 years and has varying degrees of success

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[Spetznaaz]

oh sorry, must have missed it.... some can't be moved with air hammer either.. glad it worked for you..

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I didn't think the air hammer was going to work at first but i just kept hammering away even though it wasn't budging a mm, until suddenly it started moving. My next step after that was going to be try and drill it out.

[Jayz691]

yeah that's been around 10 years and has varying degrees of success

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Yeah, I used its more to finish it off. Wont work like its intended to be used on the b7 platform, since the time rod mounts is in the way. I use the same but for knocking out the upper arms, and ither things. Comes in handy.

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