While working on my TJ last year, I stripped the threads on the driver's side front body mount. I haven't been able to find much info on how to repair these mounts. The way the firewall and footwell are shaped, you cannot cut an access hatch from the top. Besides, I have raptor lined my interior and don't want to mess that up. So, here is what I came up with.
Here's what I started with.
Using a reciprocating saw and a long thin kerf metal blade I carefully cut off the frame mount.
Then I used a 2 1/2" hole saw to cut out the bad body mount.
I've always wanted to know what up in the body, I'm sure you have too. So, here ya go
If you look carefully, you can see the threads are rounded off. Use a torque wrench boys and girls. this is basically sheet metal formed into a nut. Next, I put some 0.25" stock into my drill press and cut out a 2 1/2" disk, then welded a nut to the disk.
I bolted the body mount back together for mockup, then held the frame mount back to where it was supposed to be and tacked the new body mount into place. After a few tacks, I unbolted the mount so I had access and started stitch welding the body mount into place.
More stitching, then grinding and some primer
And finally, bolt the frame bracket to the body so the alignment is perfect, and weld it back on. Painted and finished:
Tricks for next time.
While using a hole saw, use some sort of bushing to keep the saw from moving all around. It made the hole a lot bigger than it needed to be, and took twice as long to cut.
For the new body mount, 0.25 is overkill, probably use 0.125 instead. Also, make the new mount slightly bigger than the hole you cut in the body, like 2 5/8" or 2 3/4". Dress with a flappy wheel on a grinder so you don't have to do so much stitch welding overhead.
There are probably better ways to do this, but it's what I did. Hopefully, this little write up will help someone
Here's what I started with.
Using a reciprocating saw and a long thin kerf metal blade I carefully cut off the frame mount.
Then I used a 2 1/2" hole saw to cut out the bad body mount.
I've always wanted to know what up in the body, I'm sure you have too. So, here ya go
If you look carefully, you can see the threads are rounded off. Use a torque wrench boys and girls. this is basically sheet metal formed into a nut. Next, I put some 0.25" stock into my drill press and cut out a 2 1/2" disk, then welded a nut to the disk.
I bolted the body mount back together for mockup, then held the frame mount back to where it was supposed to be and tacked the new body mount into place. After a few tacks, I unbolted the mount so I had access and started stitch welding the body mount into place.
More stitching, then grinding and some primer
And finally, bolt the frame bracket to the body so the alignment is perfect, and weld it back on. Painted and finished:
Tricks for next time.
While using a hole saw, use some sort of bushing to keep the saw from moving all around. It made the hole a lot bigger than it needed to be, and took twice as long to cut.
For the new body mount, 0.25 is overkill, probably use 0.125 instead. Also, make the new mount slightly bigger than the hole you cut in the body, like 2 5/8" or 2 3/4". Dress with a flappy wheel on a grinder so you don't have to do so much stitch welding overhead.
There are probably better ways to do this, but it's what I did. Hopefully, this little write up will help someone
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