Need advice ASAP - Can't get bolts into rusty holes

[pigpen]

Help! I'm trying to install my front skidplate before my first dirty meet tomorrow, and I can't three bolts in. The plastic heatshield was ripped off a few years ago, and the three bolts along the front edge (in the bumper beam?) haven't been in since then either. Now the threaded holes have so much rust in them, that i can't get the bolts in.

I tried giving the holes a little squirt of PB blaster and then just threading in the bolts before putting on the skidplate to get the holes cleaned up, and I can't even do that!

Does anyone with more mechanical experience than me have any suggestions? I'm mechanically challenged, and I know there are a few mechanics out there that might have some suggestions. Please help, so I can get my car dirty tomorrow without ripping off my headers or denting them any worse than they already are!

[JacksonRally]

Your best bet is to "chase" the threads with a tap. Just make darn sure its going in straight or you'll end up with a broken tap in a rusty hole. Take the bolt to either a specialty tool store or if your brave an autoparts store and have them get you the correct tap. Good Luck!

[409industries]

I had the same problem with my GC. The previous owner neglected to keep the plastic tray on, and the holes rusted up pretty good. I found that good old WD40 and some gentle pressure with the bolts would get them started.

Even though theyre able to go in now, theyre still stiff as hell. If theyre totally shot though, youll need to go with the tap...

[pigpen]

I'm going to go back out and try again. Thanks for the tips!

If anyone has anything else to add, let me know because I may be back inside very soon seeing if I really need to go out and buy a metric tap set. If I do, I really hope I can get that thing in straight.

[PSG STI]

I think Lowes still carries a metric tap set for about $40. Also make sure you've got stainless steel hardware so you don't run into another rust issue.

[pigpen]

Thanks all. I have it installed, and I'm about to head out just to make sure it doesn't fall off on some bumpy gravel roads. I ended up buying a metric tap and die set from sears for ~$40, so i'm not too upset. i was worried i was going to be spending $100 on a tap set i might only use one or two more times.

time to go get dirty :headbang:

[sebhockey]

Tap and die sets are very useful to have around. I didn't think I would use mine more than once when I got it, but it's come in useful a lot.

[MetalNeverDies]

lol i just started heling out in a mechanic shop ive already had to use it about 3 times. stupid rebuilding a vw motor