Thread Insert in Upper Door Jam Apprently Broken

I couldn’t seem to find a better place for this question.

One of the bolts that attaches the upper window frame to the rollbar apparently has the thread insert loose and moving around inside of the roll bar. The boat just turns and won’t come all the way out.

Has anyone ever experienced this and how did you go about correcting it?

Thanks for any help you can offer.

I thought I would try to get the tube off to cut off the bolt from the inside, but the torx in the photo needs a special wrench because of the stud in the middle of the torx fastener. The problem with that might be getting everything apart to cut the bolt.

Any sharing of experience with this problem, or any ideas will be greatly appreciated.

I found the sockets are called tamper proof torx. Home Depot has them. Not sure what I can do once those bolts are out.

Thanks Maclean!

I don’t think that I described the dilemma correctly. I just got back from Home depot with the tamper proof Torx bits, so I should be able to get the other bolts out for that horizontal piece above the door.

My dilemma is that the thread insert from the bottom of that tube has pulled loose from the tube and is threaded onto the end of the bolt.

I believe that if I can get the tube off, even with the upper door frame attached, I might can reach and cut off the end of the bolt. It will be a hassle finding the replacement bolt and getting it tacked in place, but where there’s a will there is a way.

Thanks Maclean.

I’m hoping so. My wife is leaving for a few days starting tomorrow. Their flight plan is for 7:30 AM wheels up, and I will be opening the hangar while they’re taxxiing out, so I hope to have it loose by 8AM, famous last words. Will tell you then if I can reach that insert.

I’m having doubts about being able to get it apart without removing more of the cage.

Well I ended up cutting the bolt. The insert is in the plastic door frame, not the steel roll bar. Not sure how I fix it unless I buy the door frame. I don’t know what size welding rod to use on the plastic.

I might end up putting in a nut with epoxy.

I’m leaving off the top and doors until Fall so I have some time to work it out.

Thanks everyone. The insert was indeed pulled from the door frame. In my younger years I would have been trying to patch it up somehow, but I just sourced a new doorframe.

Thanks for the responses.