Had a go yesterday at fitting a pair of side steps.

Now then, the larger holes towards the inside of the car are fine, as they were covered by the stickers. However, I went to screw in the 2 bolts on the inner-sill and have found 2 sheared bolts in the holes - obvioulsy where someone has tried and failed in the past!??

I was expecting to probably have to re-tap due to years of rubbish having been thrown at them, but it looks like it's either drill-out & re-tap or forget the idea completely.

So - drilling out is really going to be tricky due to lack of space if I come from the exposed inner side. But - I notice there's a plastic trim that runs the length of the side but before i try and remove can anyone advise whether I'll then be able to access the captive bolts once its removed (sorry at work now so cant take photots - but its the plastic bit you see under the doors).

...hope this makes sense!?

Unfortunately not, the plastic covers the sill which is a box section so no access to the captive nuts

Either drill them out with a right angle drill, which will be very awkward or get some studs welded in place and use nuts....??

There are various tools available to get sheared off studs out but they never seem to do what it says on the tin!!!! Pete
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Thanks for answering my question.

I'll have a go at drilling, but I can see it's not going to be easy!

Dont think welding studs is an option as a) I cant weld, and b) like the idea but the step hanger has to be pushed flush to the sill - so the thickness of the stud would throw out the alignment of the step (front to rear and with mudflap).

Anyway - i'll see how it goes with a right angled drill !!???

Cheers

Nightmare! Sounds like it may have had side steps in the past, and removed the quick way! You may have to remove the air reservoir on the RHS if you have the same problem there. If tapping out a new thread is an issue, you could try rivnuts? .
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Joe90

Luckily it's only the 2 o/s front ones that are blocked, so nothing really in the way I just need to find a decent right angle drill attachment that'll fit the gap.

But I like the sound of rivnuts - opens up a whole new part of the DIY world for me!! Maybe a silly question, but can you use aluminium rivnuts in steel ? I only ask as I assume aluminium ones will deform/grip easier ??

Cheers for the ideas.

If you have a welder you have 2 more options

Try welding a but to the sheard bolt this works well most of the time or cut a square out round the bolt then we'll a but to a plate and weld that back in to the car

staying simple and cheap, start here,
http://www.ebay.co.uk/itm/OFFSET-SCREWDRIV...460fd3d09d

using a cordless drill, you can right angle drill and use some force with the hand held top part of this.
use these bits, though expect to snap these easily.
http://www.ebay.co.uk/itm/1-4-HEX-SHANK-HS...485f6e9b0a I'm sure you can buy better quality, but for now you can get a feel of what might fit etc. -for around £15 you cant go wrong... a centre punch to get you started etc.... and wd40. oh, and a swear-word dictionary...

The last set we had like this. We cut the top off the step, (where the existing bolt holes were) drilled two holes in the step upright and simply made another top (upright section) wider than the original and used rivnuts either side of where the snapped nuts were

We then lined up the step with the new top, marked the new upright section (when fitted) and drilled it so it could be bolted to the old step upright

Craig - I must say I like your use of the word "simply" !! Surprised your note doesn't end "all that and we still made it home for tea" !!!??

I think I'll try the drilling-out option then if that fails return the steps and convince myself it looks better without them!?


But seriously - thanks for all the suggestions.