Im replacing the fender on my 7 and ive butsted one (out of the 5 i didnt) and i got one or 2 left but i busted one of the 2 that are right next to the door under the car (lower right of the fender), im sure ill bust the 2nd one as well, been sprayin the last 2 days with penatrating lube which im sure is why i didnt bust the others, anyway on to my questions

Whats the best way to drive the busted ones out?
What size bit?
will i have to re-tap the hole?

Thanks

 

ceter punch the remainder of the bolt then drill it with small bit then either use EZ out or continue increasing bit size until you get there, and yes you will need to retap if you dont get it with an EZ out.

 

never used an EZ out, ill have to find it/them
Hopefully i wont have to re-tap it lol

Thanks

 

Heat is your friend. If you have a torch, get it hot, they will come out alot easier.

 

it was a thought but no torch

 

If you've never used an easy out be warned. If you torque it enough to break it you'll be in big trouble b/c theres no driling out an tool steel hardned easy out.

 

EZOuts don't work and often break in the hole, resulting in a much larger problem.

I'm assuming you are talking about the M6 fender bolts.

Clean the area and grind the broken head flat if necessary. Carefully center punch and then SLOWLY drill through with a small (1/8") bit. Keep it centered, lubricated and go SLOW to make sure you are drilling straight. Once that is done, you will now need to drill it out the proper size to tap it. For M6, use a 5MM drill. Drill slowly with lots of lubrication, and then tap your hole. Center up the tap, oil it well and then go in a few turns. Back it out, relube and then go in a turn or two more. Repeat until you have retapped the hole.

This requires SKILL as you must keep things straight and centered.