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I'm sure this topic has been discussed many times on FTE but I am not having much luck with the search site. I have my bed flipped upside down and was curious if anyone has used an air chisel to remove the rusted bolts. I have a grinder but do not want to damage the good cross members that I plan to reuse. Also, it is tough to get down flat in the cross member channel. So if the air chisel is a good option I will go out and buy myself a new toy! Thanks in advance for your advice!
I used a Sawzall with very good results with the bed still in the truck. Cut off wheel on angle grinder for a few of the fasteners with limited access.
2nd what Jules the Great said. unless you are trying to save the bedwood, cut or break it away from the bolts and then you can cut the bolts off from top side.
I agree with Ross in regards to snapping them off , but try soaking for a few days with this penetrating oil formula (mix up a batch of 50%atf and50% acetone) I have been using that since my Dad taught me the formula when I was a kid . It works better than anything else I have ever tried .
Air chisel is better for cutting sheet metal than heavy stuff like bolts. I would think it would tear up the crossmember before cutting the bolt next to it.
Mine snapped off, too. I guess if a bolt decides to spin in the bed strips, the square hole in the strips might get boogered up. But if the strips are going top be replaced, then who cares.
Thanks for all the good advise guys! I do plan to save the boards for patterns on the new boards. They are in good enough shape for that. I have a friend that has a saw mill and I plan to use local trees that he mills. Still deciding on the bed strips. The kits are not that expensive so if I ruin them it will not be a big deal. Just have to flip the bed over, strap on the goggles, insert ear plugs, and go to town. Thanks again!
when putting a new floor in our pontoon boat I used a drill with a small hole saw. removed the plywood then used a screw driver and hammer to bust the wood from around the bolt and cut them with bolt cutters. It was fast and worked great.
OK the smart light came on and I made quick work of my express bed. I ended up grinding a vertical cut through the bold and nut, hit it with a hammer/chisel and wallah! Took me about three hours to totally dismantle. Thanks again for all the suggestions.
Vertical cut to remove bolts.
Dismantled express bed. Blue bed front was original color. She's going to be a pretty one when done!
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Thanks in advance for your advice! 
