I have a 2006 MCS convertible. While trying to change my broken/rusted right muffler strap, I decided it would be easier to remove the metal shield (which seems to protect the tailpipes and battery tray in the boot) to make my life easier. Well I just made my life harder as I snapped one of the 4 bolts that seem to hanging off the battery box used to hold the shield. So I removed the battery to see if I can access the top portion of the bolts (to install a new one) but I can't seem to access it. Has anyone one come across this before? If worse comes worst, I will just use a metal screw in place of the broken bolt to reattach the plate, but I would rather repair this correctly. Any suggestions?

 

I've done this repair before with other cars using a MIG welder. Takes some skill and perhaps practice before trying. Under a car looking up makes it a harder job but it can be done.

With the bolt snapped off, it leaves a clean surface. Then with the MIG welder, I build up the weld (in steps so as to not overheat the surrounding area) on the broken surface to a post. This does two things, first the brief heat of the weld "shocks" the rust to help free the bond. Second, the post gives you something to grab with ViseGrips. It will likely take a few attempts since the post itself breaks off and you have to start over. It will come out though. There will likely be some discoloration of the painted area but should not burn or peel off.

I learned this technique after trying to use an Easy Out and it broke inside the broken bolt. Once that happens drilling another hole will never work. The MIG trick worked great and I'll never use an Easy Out again.

 

Stinch, either I misunderstood your reply or you misunderstood the problem. That shield is held on by studs that are welded (or press fit?) into the bottom of the battery box. The nuts rust to the stud and when you try and remove them they twist the stud off the car. So there is nothing to remove but instead something that needs to be replaced, namely the stud that was connected to the car.

I am guessing the solution is to weld a new stud in place, but I don't know what other solutions are available.

The reason I am interested in this thread is that the same method (but with bigger studs) appears on other parts of the exhaust to hold it up. When I replaced my exhaust I snapped the end of one off but luckily there was enough left to get a nut on. I feel all these studs on the exhaust are a bad idea as they will all break eventually. I wish they would have used standard nuts and bolts.