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Help needed: removing glass from door

 
Old 11-27-2018, 01:35 PM
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Smitje 928
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Default Help needed: removing glass from door

'87 S4 auto

I'm preparing my car for a repaint, and am in the middle of stripping the doors. On the driver's side I've so far removed the doorguard, window motor and lifting mechanism, wire harness and the rubber window seal on the inside of the door.

Unfortunately when trying to remove the second felt pad my allen wrench snapped, leaving the head of the wrench in the bolt.....


Now I'm trying to get the glass out, but unfortunately it won't fit through the gap (the metal bracket gets stuck on the inside).

Any thoughts?








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Old 11-27-2018, 03:38 PM
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....and it's out...!!!!!!!

An hour or so of fiddling and elbow grease later I managed to slightly widen the gap using my hand and out it came!


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Old 11-28-2018, 01:18 AM
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I would suggest that you not use those Ball tools for final tightening or breaking loose any of these allen bolts .
This is a surefire way to damage the head of the bolt and or snap off the ball of the tool.
To get the broken tool out get a small punch and tap the tool bit in a few different directions,
then use a magnet and it should come out
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Old 11-28-2018, 07:51 AM
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Originally Posted by Mrmerlin View Post
I would suggest that you not use those Ball tools for final tightening or breaking loose any of these allen bolts .
This is a surefire way to damage the head of the bolt and or snap off the ball of the tool.
To get the broken tool out get a small punch and tap the tool bit in a few different directions,
then use a magnet and it should come out
Thanks so much for the advise Stan! I will give it a try when I get back home after the weekend.....
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Old 12-18-2018, 03:34 PM
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It took a couple of hours fiddling and drilling but she's out! A few days of torture, patience, 5 broken drills but they were worth it! At first I tried a magnet and some WD40 as lube, but that didn't give enough momentum to overcome the resistance the head had inside the bolt. In the end I had to drill a hole between the head of the wrench and the inside of the bolt (basically ending up drilling in the bolt as the material was slightly softer than the broken head of the Allen wrench). When the hole was deep enought I was able to get a small hook behind the head and pop it out.

Luckily I then could still get a normal allen wrench in and loosen the bolt.







And now on with the rest of the door.....

.
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