So I got my FrontRunner rack yesterday. I started removing the stock rack and I noticed the passenger rear side rail area had scuff marks. I am assuming the PO went into a garage or something that was too low. Unfortunately when I got to literally the last bolt it is spun.I don't have my dremel or angle grinder because they are at my Moms helping her with a small bath remodel. I thought maybe i could use leverage to get the weld to grab just enough to pull the bolt out. But it didn't work and I created a nice little dent.
Now i will have to figure out how to seal the hole. I figure one bolt missing won't be a huge deal but I don't want water getting in the hole. I don't want to remove the headliner.
Well onward.
I spun two bolts and they fell in the headliner. I ended up enlarging the hole slightly to put a nutsert in with some flexible marine-grade sealant for good measure. On the OEM rack, the seal is actually created by the gasket on the "foot" and not the bolts themselves. I have not had any water intrusion in the last year. Your frontrunner rack may be different.
