Snapped a fender bolt on a 2019 Civic last Tuesday and had to explain the whole thing to the customer
Last Tuesday I was pulling the front bumper on a 2019 Civic for a simple repaint job and one of the fender bolts just sheared right off at the head. I hit it with penetrating oil twice over 20 minutes, used the right socket, and it still twisted off like it was made of butter. Had to drill it out and run a tap through the hole, which turned a 2 hour job into a 4 hour job and a phone call to the customer explaining why his quote went up $85. My question for you all is simple: do you eat that kind of thing on the quote or do you pass it on? I passed it on and the guy was fine with it, but I still felt like a rookie for not feeling it start to give.
That bolt probably had thread locker or corrosion you couldn't see, so feeling it start to give wasn't happening no matter how good you are. Passing it on was the right call, hidden rust isn't your fault and the customer gets that when you explain it straight.