Removing gas tank skid plate...

2005 Sport, 6 cyl, 266k. I noticed my rear gas tank strap rusted out and I got 4 off the 5 skid plate bolts out but the front drivers side bolt is a real bear and I've stripped the head something fierce. My Irwin bolt removers are just tearing it up more, as did the vise grip. I tried drilling a hole in the washer and driving it loose but everything is really frozen. Used heat and lots of penetrant. Someone suggested welding another bolt head (nut) on, but I don't weld. I ordered a set of grip tite sockets, but if that doesn't work, I'm thinking of using my dremel to cut around the bolt, remove the skid plate, and do whatever other surgery I need to do to get the bolt out, and then just use a large washer to put it back together. Other suggestions?

 

If its one of the 3 bolts in a row on the drive side frame rail, I'd say you could go with out it. If you want to get a new bolt in there for peace of mind and are okay with drilling and tapping the hole out, can just cut the head off and remove the skid. To get a new bolt in that hole, would just need to drill out whats left of the rusty bolt in there and tap with m8x1.25

I have a writeup on Tank Strap replacement on T4R, I hope its not frowned upon to reference over there: Heres what mine looked like:

 

Thanks. I'll check it out. It looks like you cleaned up your frame nicely. What did you have to do?

 

I did wire wheel on a grinder, then painted with rustoleum rust reformer and an exterior spraypaint on top of that. It was all surface rust there, just looks kinda bad with the peeling paint

 

I have a hole in the frame near the driver's rear wheel. Not sure what I'm going to do after I replace the straps and the rear brake lines.

 

I finally got this bolt out. It took the umpteenth try, repeated penetrant, and really pounding on a size smaller Irwin bolt remover (went from 12 mm to 11 mm).

 

I would definitely get the frame repaired. Get a pro to do it, since you don’t weld. It shouldn’t be a big deal, I’ve seen worse than that.
Good perseverance with the bolt! My go to method for rusty bolts is heat. Although around fuel tanks you need to be careful, for sure.

 

I did use benzene for heat but was skittish about doing too much cause of the fuel tank.

I definitely plan in getting someone to do sd something about the frame. I wish Toyota would step up.