While replacing the motor for the headlight I ended up breaking the bolts that attach the headlight bracket to the car and am unable to drill them out. I've been told that the Pontiac Firebird often used the same headlight parts, but I am curious as to what others have done or would do in this case, or if anyone else knows if the Firebird lights are compatible.

 

I believe the only thing in common they have is the gear inside the motor. Same size and number of teeth.

Can you please post a picture of the headlight showing the issue you are having?

 

I hope this helps. The bracket on the headlight assembly had 7mm bolts that attach it to the hinge on the body, but due to rust they all broke

 

I'm sure I'm being a moron, but why can they not be drilled out, and where are they in the picture? Are they broken flush with the headlight mount?

 

I have tried to drill them out, but unfortunately the middle of all the bolts are made of some ridiculously strong metal or something and have broken 3 different bits. The outcropping on the left side by my hand and directly in front of the spring on the right side both have two bolts that hold it to the holes in the hinge. They were in fact broken flush, as well.

 

A lot of cleaning and prepping and maybe some JB Weld? That's completely off the top of my head without looking closely at it. The fact that the bolts broke off flush means you have nothing protruding from that surface, so that may leave you with two flat surfaces with a lot of overlapping surface area to bond together.

It becomes kind of permanent this way, but what are the chances of you needing to go in there again?

 

You're putting too much pressure on a small bit. Try a bit that will fill the hole and make sure it's a NEW one with a sharp tip. If there's anyway you can get a small block of wood under the flange where the bolts broke off and get someone to hold it for you that would help. If not, then try a clamp of some kind. You need to have a solid surface backing the hole as you try to drill it. Take your time and put a little oil on the bit to keep it from getting too hot. Those should be able to be drilled out. If you can remove the whole assembly (and it looks like it), remove the assembly and take it to a work bench. Or to someone that has a drill press. If you're doing the other one too, I'd suggest you soak the bolts thoroughly with some rust penetrating juice. My go to is Kroil.