Does anyone know how to loosen the screws in the body for the door hinges. I have tried an impact driver and it started twisting the bit and still doesn't loosen and also a hex shaft screw driver with a wrench on the shaft and broke the tip. My next idea is to fit a philips bit to an air operated impact wrench but am afraid it will destroy the screw.

Thanks in advance for any help.

You're going to have to destroy them no matter what at this point. If they don't come out w/ the impact you'll end up drilling them out.  I had about half of them come out w/ the impact and the other half I had to drill out. Start w/ a small pilot bit and work you way up, this way you're always drilling in the center of the screw.  By the time you get to the last size bit you'll actually start threading the screw in further.  Just reverse the drill and it'll come right out w/ the bit. The goal is not to destroy the threads on the body.  Good luck and stay patient!

Snap on makes a manual impact (name ) You insert the screw driver tip in it and then hit the end with a heavy hammer. When the handel bottoms out it turns the screw. It worked on all of mine. Luckily my friend had one, because I would of just drilled it out before I spent the $'s on the snap on tool.
Zig

You should check with your local auto parts store's tool section and look for what are called screw extractors. What you do is drill out the center of your screws and then use the screw extractor to just back it out as if it were a screwdriver bit. I use them all the time for my Air Force job and can say that the work a lot of GOOD magic.  

Buy your self an impact driver, even at a cheap tool shop it will get you through, I picked one up for $30.00 CDN, you will get them out that way, or take a chisel and notch one side of the screw head, and then take a square punch or a screw driver and hit the notch from the side and the screw will back out.

Mac

when i was making the change from soft top to hard top the braket on the right side just wouldnt come out..si i hit the screw driver with a hammer while it was in the screw and that worked to get them all out...

dont know if that will help u or not...think like the pickle jar when it just wont open lol a good whack and itl move

You might want to try a left-handed drill bit. I cuts going counter-clockwise and will extract the screw as it drills. Think Snap-on sells them.

Snap on makes a manual impact (name ) You insert the screw driver tip in it and then hit the end with a heavy hammer. When the handel bottoms out it turns the screw. It worked on all of mine. Luckily my friend had one, because I would of just drilled it out before I spent the $'s on the snap on tool.
Zig

Thats what I did. After some cussing and screaming, this tool got them out for me to..

Does anyone know how to loosen the screws in the body for the door hinges. I have tried an impact driver and it started twisting the bit and still doesn't loosen and also a hex shaft screw driver with a wrench on the shaft and broke the tip. My next idea is to fit a philips bit to an air operated impact wrench but am afraid it will destroy the screw.

Thanks in advance for any help.

Make sure you are using the impact driver correctly. I didn't at first and realized I was tempting to tighten the screw head. What indicated this was how the bit was messing the head of the screw.

Impact driver wouldn't move mine. Impact wrench just broke bits.

Used a dremel cut off wheel to trim off two sides of the screw heads. Ended up with two flat spots that I could grab with a cresent wrench.

Crescent wrench turned the screws right out.  No farting around drilling, no mucked up threads.

If the impact driver(type you hold pressure on it and hit with a hammer) didn't work i use a little heat from my MAPP gas torch. Gets them out every time so far. If you already screwed up the philips head then I'd try the cutting flats method and cranking them out with a crescent wrench.

 When I very first found out about doing body work, and about Suzukis (SJ410s and sammies), I had a very good teacher. He had done many sammies and other zuks over the years and had a great wealth of knowledge of shortcuts. This was about 15 years ago, when sammies were relatively new to the US.
How he tought me to deal with the stubborn zuki screws, was to use not an impact driver, but to use a center punch. You strike the screw near the shoulder on the flat of the screw in a counter clockwise hit, use a larger hammer, mine of choice is a 3.5 pounder, and try not to angle the punch too sharply. About a 10 degree angle to start, then after you have a good divet started, increase to about 20 degrees. If you do this to every screw before you destroy them with the wrong screwdriver or worse, you will never have a problem with them. By the way, use a number 3 philips. That is the proper size to deal with the body screws. This trick will also work with the windshield frame screws.

Use heat.... Suzuki used as thread locker that is too effective.....  Use a micro torch so that you don't burn any surrounding paint.  One it's heated, a couple of shots with a impact driver and they come right out.... I think the key is to soften the thread locker......

I agree with Idaholwb, thats exactly how I got my screws out of my sammy.  Only, I did this AFTER I purchased a new impact driver!  I used a chisel, because I didn't plan on putting the phillips screws back in.  I went to the hardware store and got some flanged head bolts.  

D

I had to EZ Out a couple of mine.