Neglected Thule Roof Bar Removal

So, this evenings buggering about just before I go on holiday involved removing the Thule Areo roof bars and bike racks from my car and fit the square roof bars and roof box.

Should have taken about 20 minutes. 2 hours later a one very corroded bolt in the roof bar  foot means that it’s not coming off. The foot in question is a Thule 755 for open roof rails. The hollow bolt inside the foot has a square hole through it that the aero bar end caps / square rod tensioner fits into. It’s so tight / corroded that the square rod is now a spiral.

I’ve tried soaking the bolt with GT85, Plusgas, fitting the square rod into a 4mm socket and attacking it with an impact driver.

Still solid.

Next option is either drill the bolt out of the plastic housing of the foot or cutting the whole thing off with a reciprocating saw.

Any ideas before I go nuclear?

* Please don’t say regularly removing the roof bars and lubing the bolts

Photos?

Leave it on for now and fit the other set in a slightly different position?

Also try tightening it a bit before loosening

I can’t upload photos since the new servers went online.

https://www.roofracks.co.uk/foot-assembly-single-used/p/2327

I’ve tried tightening, it’s absolutely solid.

The only way I can see to remove it is to cut the plastic around the bolt head or to drill the bolt head out. Either way it destroys the foot.

I took a set off with just a hacksaw (piece of piss) they are only plastic and don’t take much cutting.

Why do you need to change them?

New car day, Shirley?

Split the square nut?

T Track adapters for the roof box?

T Track adapters for the roof box?

https://www.ebay.co.uk/itm/284651894544?_trkparms=amclksrc%3DITM%26aid%3D777008%26algo%3DPERSONAL.TOPIC%26ao%3D1%26asc%3D20240131095853%26meid%3D8f052f17514b4206b95ff6cf7d09e938%26pid%3D101949%26rk%3D1%26rkt%3D1%26itm%3D284651894544%26pmt%3D1%26noa%3D1%26pg%3D4375194%26algv%3DRecentlyViewedItemsV2WithMLRV6RankerPricelessTop30Features&_trksid=p4375194.c101949.m162918&_trkparms=parentrq%3Aedfc30b01900acda40e9c749fffec826%7Cpageci%3A5eb8dfd8-4b22-11ef-87e8-5eaeab494ac0%7Ciid%3A1%7Cvlpname%3Avlp_homepage

To answer a few questions.

I can’t get at the square but to split it, the foot has the aero bar on top and fitted to the car.

I could fit the roof box with T slot bolts, but I need to move the seized foot to align with the roof box mounting points. The roof box would be over hanging the boot lid by too much. I wouldn’t be able to get into the boot.

So far it looks like destroying the foot and then find a replacement at a later date.

Moral of the story is don’t forget to lubricate your nuts.

Moral of the story is don’t forget to lubricate your nuts.

And if you have the screw down vertically type of roof fitting also buy the relevant blind tap set and chase the threads out a couple of times a year.  Saves lots of swearing and squeaking bolts.  ?