Roof Rail Channel Bolts Cross Thread Issue

[9 Foot Shark]

hi. I’m stuck. I have a T6 and a problem with the gutter rail bolts area.
Firstly I have a snapped bolt that I’m going to have to drill out, secondly a bolt had been cross threaded into the housing. The question I have is .. is it possible to replace the bolt housing inside the body work? Has anyone ever done this??

 

[Dellmassive]

hmm . . . . it might be easier to just drill it out (the stuck bolt and welded nut inside) slightly oversize and replace it with a longer bolt + nut.

the existing nut is hard to get too and you might damage the external bodywork trying to grind it off and spotweld a new one in.

 

[9 Foot Shark]

Got the stuck bolt out rather easy so quite pleased with that effort.

The internal bolt is the biggest issue. Using an M6 tap it’s rather risky. What if it snaps or I can’t get the tap out.

 

[Dellmassive]

Then drill it with a cobalt bit.

 

[Dig]

HI 9 foot
How did you get on with this (Im a new member)? I have a similar problem with a cross threaded roof bolt nut that i need to tap/ use a helicoil perhaps.
Do you know if they are M5 or M6 ?
Thanks in advance