I got the drivers side door bar out and it took me 4 hours. All the nuts and bolts too. This is not an easy thing to accomplish. I don't care what anybody say's, this is not easy.
Here is what I did. I went to Sears and looked over all the tools. My wife brings me a bolt-out remover. Part #952166 low profile to work in tight spots. I said good find baby. I think this will work. $20. She was SOO proud of herself
Slip this thing over the 15mm nut and put a regular combination wrench on it and turn. This nut loosened right up and took it off the rest of the way with my fingers. I said to myself "man this is going to be a piece of cake".
WRONG. Those 2 10mm bolts ( the 15mm is a nut and the 10mm's are bolts ) have a smooth shank on them. The shank is wider than the threaded section.
I put the 10mm bolt extractor on the outside bolt "closest to the front of the car" and slid a combination wrench on it and it broke loose but would never loosen up because of the smooth shank. This bolt faught me all the way. Little turns at a time while the bolt extractor decided to fall into the door bar itself
I had a flexable magnet on hand an with a little aggrivation I got it out. This proceedure happened 4 or 5 times so I was getting pissed. I took a deep breath and continued
I got the bolt out far enough to get a 10mm wratchet wrench on there and at this point it came out pretty fast but it was tight the whole way out till the very last turn. NO WAY can someone back these out by hand. NO WAY. At least in my 99 Camaro you ain't.
OK, 1 more 10 mm to go. This one the bolt extractor wouldn'r work because it is protected by lots of steel. Couldn't get the wrench on it to loosen it. I had to grind down a 10 mm socket. WAY DOWN till it barely would work. Now I backed out the 10mm with a regular 1/4" wratchet a few turns at a time until I had to stop or I wasn't gonna get the wratchet off the bolt because it was pinned against the door skin. I barley got the wratchet off the bolt and again I used a 10mm wratchet wrench to get it out the rest of the way. This bolt ALSO fought me all the way till the last turn. It was tight the whole way out.
OK, Now I got to get the door bar out. I left it in place and used a small air cutting tool with a thin disc. You need to very very careful because this bar is really close to the door skin. One slip and, well we won't go there
Anyway that is why I used this tool very carefully. Took about 1/2 hour to cut through and take about 6 or 7 inches off the bar.
At this point I was able to pull the door bar out of its perches and pull the bar close to me or away from the door skin. I then made another cut off with a saw zaw and a short metal cutting blade. This cut off was about a foot long and it was quick with the saw zaw. The door bar still wouldn't come out so I had to make another cut and it was done.
I bribed my wife to vacuum the shavings from the inside of the door and I went right to the fridge and popped open one of those Mike's Hard Lemonade's
I am having a Hard Lemonade as I type wondering why in the SAM HELL I even started this weight reduction mod.
OH ya I almost forgot. Before the MHL I weighed the bar pieces less the bolt and nuts on my bathroom scale. Not very accurate but it said 7lbs. I'll take these pieces to the Post Office tomorrow and weigh them.
So there you have it folks. If you want to drive yourself crazy for 14 or 15 lbs. be my quest.
One more side to go
I'm gonna get me another lemonade