Half way through doing my rear disk conversion and its turning out to be harder than the engine swap! i decided to change the hubs and not the whole trailing arms since they were twisted on my doner car only the heads on the 4 star drive bolts keep rounding off, they are a bit rusty. tried every thing i can think of: heat, impact driver, nothing seems to work. ive done one side by drilling them out but they are hard as hell, ive gone through ~7 drill bits so far and and it took most of the weekend with a pillar drill and thats only 4 bolts! and im tackling the other this weekend, any ideas?

cant get replacement arms, prices too steep on second hand jap parts round here

(seriously gutted cos i used to work for the company that made them, i used to test the trailing arms, i could have walked out with a pair!!!!)

 

you are trying to disassemble the splindle from the arm, right? i know this because i had to do the same thing to add rear disc brakes to my wagon. i ended up drilling the bolts out from the hub side using titanium bit and and air powered die grinder with a metal grindng bit. if you don't have air tools i feel bad for you. good luck

 

i had to do the same thing with my disc conversion on my 91 hatch. What i did was heated up the bolts with a torch and then just took them off with an air rachet. They came off easy after i heated them up (pain in the *** before, i broke like 4 or 5 hex bits).

 

yea forgot to mention, no access to air tools as the buisiness has just changed premises and we left the compresor( and the two post ramps) cos we thaught we wouldn't find a place with three phaze electricity only to find one a few months later! gutted.
any other ideas? any other halp would be much appreitiated as im doin the job at the weekend.