Torsion bar bolt snapped

1. s555dan Regular Poster Joined: Feb 2010 Bristol Posts: 493 16v'd Saxo VTR Mk1 Astra G Coupe 1.8

   #1 6th February 2011, 23:35

   Well it seems my track car build is one problem after another
   
   So today I started to lower the rear.
   
   Firstly i discovered a rusty rear arch which is more of a hole throught to the boot. This was not the greatest of starts but i decided to continue on.
   
   I removed the anti roll bar easily, 12mm bolt worked a treat.
   
   I then came to the torsion bar torx bolt on the drivers side.
   
   It was very stiff but it was moving slowly and steadily.... it then freed up as if it magically loosend. A few turns later and the head of the bolt drops off leaving 90% of the bolt still in the torsion bar.
   
   As if things couldnt get any worse
   
   
   Anyways, the plan is to drill it out and try an easy out. If this doesnt work I'll try re tapping it - obviously need a thread of some sort for the slide hammer.
   
   Has anyone had to do this and if so what method do you find easiest etc
   
   Whats the advice on tackling the other torsion bar bolt to prevent this happening again.
   
   Thanks
   
   Dan
2. s555dan Regular Poster Joined: Feb 2010 Bristol Posts: 493 16v'd Saxo VTR Mk1 Astra G Coupe 1.8

   #2 7th February 2011, 13:02

   Any views on this?
3. MartinDines Established Member Joined: Nov 2010 Canvey Island, Essex Posts: 1221 Citroen Saxo 1.4 Furio

   #3 7th February 2011, 20:19

   Done exactly this.
   
   Used an easy out, which then snapped inside the torsion bar aswell fml.
   Tried to machine it out using special tips but no luck.
   
   Bought new bars off here for 20quid lol result
4. Mochachino Saxperience Hardcore! Joined: Nov 2007 Guantanamo Bay Posts: 28700 oyster card

   #4 7th February 2011, 20:21

   Chizle it out. Dont use a slide hammer couse theyre pointless you are better off blowing on the torsion bar.
5. bourney Infrequent Poster Joined: Aug 2010 Posts: 121

   #5 7th February 2011, 20:36

   mate, i'd hate to be you right now! i hate getting snapped bolts out, it's a pain in the arse.
   If you do drill it and try an easy out be sure not to snap it, they're made of hardend steel and damn near impossible to drill!
6. s555dan Regular Poster Joined: Feb 2010 Bristol Posts: 493 16v'd Saxo VTR Mk1 Astra G Coupe 1.8

   #6 7th February 2011, 21:05

   Quote:

   Originally Posted by MartinDines Done exactly this. Used an easy out, which then snapped inside the torsion bar aswell fml. Tried to machine it out using special tips but no luck. Bought new bars off here for 20quid lol result

   I did wonder if the easy out would snap too
   
   How did you get the bar out if you didnt have a thread?
   
   I thought the only options to get torsion bars out was slide hammer or threaded bar and nut?
7. seddon89 Frequent Poster Joined: Jul 2010 gateshead Posts: 807 vw golf GTI citroen saxo forte 02 plate vw polo

   #7 7th February 2011, 21:10

   we used a piece of solid copper bar when we done mine mate, it took a few belts but they came out
8. s555dan Regular Poster Joined: Feb 2010 Bristol Posts: 493 16v'd Saxo VTR Mk1 Astra G Coupe 1.8

   #8 7th February 2011, 21:12

   Quote:

   Originally Posted by db_sax Chizle it out. Dont use a slide hammer couse theyre pointless you are better off blowing on the torsion bar.

   Thanks for the tip
   
   So a long narrow chizzle will remove all the length of screw?
   
   Whats a better method than the slide hammer, i was using the badgermotosport guide and they made it look easy with the slide
   
   
   

   Quote:

   Originally Posted by bourney mate, i'd hate to be you right now! i hate getting snapped bolts out, it's a pain in the arse. If you do drill it and try an easy out be sure not to snap it, they're made of hardend steel and damn near impossible to drill!

   Haha i think you would hate to be me anytime when it comes to mechanics, im forever snapping and breaking everythin. Half my mods are replacements for the things i break
9. s555dan Regular Poster Joined: Feb 2010 Bristol Posts: 493 16v'd Saxo VTR Mk1 Astra G Coupe 1.8

   #9 7th February 2011, 21:14

   Quote:

   Originally Posted by seddon89 we used a piece of solid copper bar when we done mine mate, it took a few belts but they came out

   So you dont have to pull them out from the beam?
   
   You can bash them through? Dont they hit on the inside of the opposite leg
10. seddon89 Frequent Poster Joined: Jul 2010 gateshead Posts: 807 vw golf GTI citroen saxo forte 02 plate vw polo

    #10 7th February 2011, 21:18

    which one ya snapped the bolt in
11. s555dan Regular Poster Joined: Feb 2010 Bristol Posts: 493 16v'd Saxo VTR Mk1 Astra G Coupe 1.8

    #11 7th February 2011, 21:21

    Its the drivers side one that bolts the bar into the suspension leg.
12. seddon89 Frequent Poster Joined: Jul 2010 gateshead Posts: 807 vw golf GTI citroen saxo forte 02 plate vw polo

    #12 7th February 2011, 21:25

    ya should be able to get it out, but not to put hammer rash on the bar as it will not come out
13. s555dan Regular Poster Joined: Feb 2010 Bristol Posts: 493 16v'd Saxo VTR Mk1 Astra G Coupe 1.8

    #13 7th February 2011, 21:28

    What the hell is hammer rash lol? thats one for a google seach brb
14. seddon89 Frequent Poster Joined: Jul 2010 gateshead Posts: 807 vw golf GTI citroen saxo forte 02 plate vw polo

    #14 7th February 2011, 21:31

    bashing the end of the torsion bar into a mustroom shape so ya cannot get it out lol
15. s555dan Regular Poster Joined: Feb 2010 Bristol Posts: 493 16v'd Saxo VTR Mk1 Astra G Coupe 1.8

    #15 7th February 2011, 21:42

    mustroom lol, I know what you mean!
    
    Can you remove the bar completly bar bashing it through?
    
    Isnt the other end of the torsion bar inside splines on both ends?
16. seddon89 Frequent Poster Joined: Jul 2010 gateshead Posts: 807 vw golf GTI citroen saxo forte 02 plate vw polo

    #16 7th February 2011, 21:45

    yeah, take the other bolt and locking disk out first lol it should come out with a few good belt and watch ya fingers mate lol

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