I'm upgrading my crumbling factory mounts to Daystar polys and despite
drilling 1/8" holes in the tub and shooting it with PB Blaster for a week I
managed to still snap three of the bolts - the two between the front seats
and the rollbar and the rearmost driver side.

My plan of attack on the rear mount was to cut an opening in the rear of the
body large enough to grind off the ears that hold the nut and lift the thing
out and replace with a standard washer/nut. My passenger side rear mount
bolt fell out at some point before I got this Jeep so I had previously
slotted that side and used just a regular washer and nut as the factory nut
had no more thread and I couldn't really tap for the next size up.

I thought I may be able to get the rollbar mounts if I drill the bolt out
from both the top and bottom but I ended up snapping off a drill bit in the
top of one of them - darn! I still have about 2-3" of bolt in there so I
can't really go at it from just one end. Should I just not bother and cut
the opening large enough to grind out the ears holding in the nut and do the
same as in the rear? The bolts seem pretty soft but now that I have a bit
stuck in there it's going to be really rough drilling through that one.

Any comments from someone who's been through this? I'd rather not cut up the
floor more than I have to but I'm afraid I don't have much choice at this
point. Luckily I was able to get all the other bolts out relatively easily.

-jd

'94 YJ

 

Oxy-Acetylene, or that sabre saw, you've always wanted. I surely
wouldn't weaken an already too weak area.
God Bless America, ßill O|||||||O
mailto:-------------------- http://www.----------.com/

jdarg wrote:
>
> I'm upgrading my crumbling factory mounts to Daystar polys and despite
> drilling 1/8" holes in the tub and shooting it with PB Blaster for a week I
> managed to still snap three of the bolts - the two between the front seats
> and the rollbar and the rearmost driver side.
>
> My plan of attack on the rear mount was to cut an opening in the rear of the
> body large enough to grind off the ears that hold the nut and lift the thing
> out and replace with a standard washer/nut. My passenger side rear mount
> bolt fell out at some point before I got this Jeep so I had previously
> slotted that side and used just a regular washer and nut as the factory nut
> had no more thread and I couldn't really tap for the next size up.
>
> I thought I may be able to get the rollbar mounts if I drill the bolt out
> from both the top and bottom but I ended up snapping off a drill bit in the
> top of one of them - darn! I still have about 2-3" of bolt in there so I
> can't really go at it from just one end. Should I just not bother and cut
> the opening large enough to grind out the ears holding in the nut and do the
> same as in the rear? The bolts seem pretty soft but now that I have a bit
> stuck in there it's going to be really rough drilling through that one.
>
> Any comments from someone who's been through this? I'd rather not cut up the
> floor more than I have to but I'm afraid I don't have much choice at this
> point. Luckily I was able to get all the other bolts out relatively easily.
>
> -jd
>
> '94 YJ

 

Oxy-Acetylene, or that sabre saw, you've always wanted. I surely
wouldn't weaken an already too weak area.
God Bless America, ßill O|||||||O
mailto:-------------------- http://www.----------.com/

jdarg wrote:
>
> I'm upgrading my crumbling factory mounts to Daystar polys and despite
> drilling 1/8" holes in the tub and shooting it with PB Blaster for a week I
> managed to still snap three of the bolts - the two between the front seats
> and the rollbar and the rearmost driver side.
>
> My plan of attack on the rear mount was to cut an opening in the rear of the
> body large enough to grind off the ears that hold the nut and lift the thing
> out and replace with a standard washer/nut. My passenger side rear mount
> bolt fell out at some point before I got this Jeep so I had previously
> slotted that side and used just a regular washer and nut as the factory nut
> had no more thread and I couldn't really tap for the next size up.
>
> I thought I may be able to get the rollbar mounts if I drill the bolt out
> from both the top and bottom but I ended up snapping off a drill bit in the
> top of one of them - darn! I still have about 2-3" of bolt in there so I
> can't really go at it from just one end. Should I just not bother and cut
> the opening large enough to grind out the ears holding in the nut and do the
> same as in the rear? The bolts seem pretty soft but now that I have a bit
> stuck in there it's going to be really rough drilling through that one.
>
> Any comments from someone who's been through this? I'd rather not cut up the
> floor more than I have to but I'm afraid I don't have much choice at this
> point. Luckily I was able to get all the other bolts out relatively easily.
>
> -jd
>
> '94 YJ

 

Oxy-Acetylene, or that sabre saw, you've always wanted. I surely
wouldn't weaken an already too weak area.
God Bless America, ßill O|||||||O
mailto:-------------------- http://www.----------.com/

jdarg wrote:
>
> I'm upgrading my crumbling factory mounts to Daystar polys and despite
> drilling 1/8" holes in the tub and shooting it with PB Blaster for a week I
> managed to still snap three of the bolts - the two between the front seats
> and the rollbar and the rearmost driver side.
>
> My plan of attack on the rear mount was to cut an opening in the rear of the
> body large enough to grind off the ears that hold the nut and lift the thing
> out and replace with a standard washer/nut. My passenger side rear mount
> bolt fell out at some point before I got this Jeep so I had previously
> slotted that side and used just a regular washer and nut as the factory nut
> had no more thread and I couldn't really tap for the next size up.
>
> I thought I may be able to get the rollbar mounts if I drill the bolt out
> from both the top and bottom but I ended up snapping off a drill bit in the
> top of one of them - darn! I still have about 2-3" of bolt in there so I
> can't really go at it from just one end. Should I just not bother and cut
> the opening large enough to grind out the ears holding in the nut and do the
> same as in the rear? The bolts seem pretty soft but now that I have a bit
> stuck in there it's going to be really rough drilling through that one.
>
> Any comments from someone who's been through this? I'd rather not cut up the
> floor more than I have to but I'm afraid I don't have much choice at this
> point. Luckily I was able to get all the other bolts out relatively easily.
>
> -jd
>
> '94 YJ

 

Oxy-Acetylene, or that sabre saw, you've always wanted. I surely
wouldn't weaken an already too weak area.
God Bless America, ßill O|||||||O
mailto:-------------------- http://www.----------.com/

jdarg wrote:
>
> I'm upgrading my crumbling factory mounts to Daystar polys and despite
> drilling 1/8" holes in the tub and shooting it with PB Blaster for a week I
> managed to still snap three of the bolts - the two between the front seats
> and the rollbar and the rearmost driver side.
>
> My plan of attack on the rear mount was to cut an opening in the rear of the
> body large enough to grind off the ears that hold the nut and lift the thing
> out and replace with a standard washer/nut. My passenger side rear mount
> bolt fell out at some point before I got this Jeep so I had previously
> slotted that side and used just a regular washer and nut as the factory nut
> had no more thread and I couldn't really tap for the next size up.
>
> I thought I may be able to get the rollbar mounts if I drill the bolt out
> from both the top and bottom but I ended up snapping off a drill bit in the
> top of one of them - darn! I still have about 2-3" of bolt in there so I
> can't really go at it from just one end. Should I just not bother and cut
> the opening large enough to grind out the ears holding in the nut and do the
> same as in the rear? The bolts seem pretty soft but now that I have a bit
> stuck in there it's going to be really rough drilling through that one.
>
> Any comments from someone who's been through this? I'd rather not cut up the
> floor more than I have to but I'm afraid I don't have much choice at this
> point. Luckily I was able to get all the other bolts out relatively easily.
>
> -jd
>
> '94 YJ

 

Had a related problem yesterday. Trying to get the bolts out, the plates
rotated and just ripped the box that holds them in place. Not sure if your
YJ is different but my 76 CJ has square pieces of plate steel that the bolt
goes into. I thought they were the same. There's like a small box that's
welded over the plates that lets the plates shift a little for adjustment
but won't let them turn. That's not the case with your YJ?
Good Luck,
Jim
"jdarg" <ruhle@hotmail.com> wrote in message
news:1Q3Tc.562485$pF1.63416@news.easynews.com...
> I'm upgrading my crumbling factory mounts to Daystar polys and despite
> drilling 1/8" holes in the tub and shooting it with PB Blaster for a week
I
> managed to still snap three of the bolts - the two between the front seats
> and the rollbar and the rearmost driver side.
>
> My plan of attack on the rear mount was to cut an opening in the rear of
the
> body large enough to grind off the ears that hold the nut and lift the
thing
> out and replace with a standard washer/nut. My passenger side rear mount
> bolt fell out at some point before I got this Jeep so I had previously
> slotted that side and used just a regular washer and nut as the factory
nut
> had no more thread and I couldn't really tap for the next size up.
>
> I thought I may be able to get the rollbar mounts if I drill the bolt out
> from both the top and bottom but I ended up snapping off a drill bit in
the
> top of one of them - darn! I still have about 2-3" of bolt in there so I
> can't really go at it from just one end. Should I just not bother and cut
> the opening large enough to grind out the ears holding in the nut and do
the
> same as in the rear? The bolts seem pretty soft but now that I have a bit
> stuck in there it's going to be really rough drilling through that one.
>
> Any comments from someone who's been through this? I'd rather not cut up
the
> floor more than I have to but I'm afraid I don't have much choice at this
> point. Luckily I was able to get all the other bolts out relatively
easily.
>
> -jd
>
> '94 YJ
>
>

 

Had a related problem yesterday. Trying to get the bolts out, the plates
rotated and just ripped the box that holds them in place. Not sure if your
YJ is different but my 76 CJ has square pieces of plate steel that the bolt
goes into. I thought they were the same. There's like a small box that's
welded over the plates that lets the plates shift a little for adjustment
but won't let them turn. That's not the case with your YJ?
Good Luck,
Jim
"jdarg" <ruhle@hotmail.com> wrote in message
news:1Q3Tc.562485$pF1.63416@news.easynews.com...
> I'm upgrading my crumbling factory mounts to Daystar polys and despite
> drilling 1/8" holes in the tub and shooting it with PB Blaster for a week
I
> managed to still snap three of the bolts - the two between the front seats
> and the rollbar and the rearmost driver side.
>
> My plan of attack on the rear mount was to cut an opening in the rear of
the
> body large enough to grind off the ears that hold the nut and lift the
thing
> out and replace with a standard washer/nut. My passenger side rear mount
> bolt fell out at some point before I got this Jeep so I had previously
> slotted that side and used just a regular washer and nut as the factory
nut
> had no more thread and I couldn't really tap for the next size up.
>
> I thought I may be able to get the rollbar mounts if I drill the bolt out
> from both the top and bottom but I ended up snapping off a drill bit in
the
> top of one of them - darn! I still have about 2-3" of bolt in there so I
> can't really go at it from just one end. Should I just not bother and cut
> the opening large enough to grind out the ears holding in the nut and do
the
> same as in the rear? The bolts seem pretty soft but now that I have a bit
> stuck in there it's going to be really rough drilling through that one.
>
> Any comments from someone who's been through this? I'd rather not cut up
the
> floor more than I have to but I'm afraid I don't have much choice at this
> point. Luckily I was able to get all the other bolts out relatively
easily.
>
> -jd
>
> '94 YJ
>
>

 

Had a related problem yesterday. Trying to get the bolts out, the plates
rotated and just ripped the box that holds them in place. Not sure if your
YJ is different but my 76 CJ has square pieces of plate steel that the bolt
goes into. I thought they were the same. There's like a small box that's
welded over the plates that lets the plates shift a little for adjustment
but won't let them turn. That's not the case with your YJ?
Good Luck,
Jim
"jdarg" <ruhle@hotmail.com> wrote in message
news:1Q3Tc.562485$pF1.63416@news.easynews.com...
> I'm upgrading my crumbling factory mounts to Daystar polys and despite
> drilling 1/8" holes in the tub and shooting it with PB Blaster for a week
I
> managed to still snap three of the bolts - the two between the front seats
> and the rollbar and the rearmost driver side.
>
> My plan of attack on the rear mount was to cut an opening in the rear of
the
> body large enough to grind off the ears that hold the nut and lift the
thing
> out and replace with a standard washer/nut. My passenger side rear mount
> bolt fell out at some point before I got this Jeep so I had previously
> slotted that side and used just a regular washer and nut as the factory
nut
> had no more thread and I couldn't really tap for the next size up.
>
> I thought I may be able to get the rollbar mounts if I drill the bolt out
> from both the top and bottom but I ended up snapping off a drill bit in
the
> top of one of them - darn! I still have about 2-3" of bolt in there so I
> can't really go at it from just one end. Should I just not bother and cut
> the opening large enough to grind out the ears holding in the nut and do
the
> same as in the rear? The bolts seem pretty soft but now that I have a bit
> stuck in there it's going to be really rough drilling through that one.
>
> Any comments from someone who's been through this? I'd rather not cut up
the
> floor more than I have to but I'm afraid I don't have much choice at this
> point. Luckily I was able to get all the other bolts out relatively
easily.
>
> -jd
>
> '94 YJ
>
>

 

I had a similar problem last winter installing a 1" MORE body lift on my 94
YJ. The rear left snapped lust like yours, I did the same thing with a bolt
& washr. However, I couldn't get the old square captive nut for the mount
out, so I just drove it up into the rear crossmember and stuck it inplace
with some body sealer.

Even thougfh I'd done as you (without the extra holes) and soaked the bolts
down with PB Blaster I had one of the main bolts come out with the threads.
I insalled a helicoil and reinstalled all new factory hardware. So far, so
good.

In your case I'd just bitethe bullet and cut in from the top with a hole saw
which you can follow with a metal or rubber plug. This is a comon problem
with SWB Jeeps that have spent time in road salted areas or along the
coasts.


"Drink" <drink@gnt.net> wrote in message
news:cglhqh$8rf$1@news.utelfla.com...
> Had a related problem yesterday. Trying to get the bolts out, the
plates
> rotated and just ripped the box that holds them in place. Not sure if
your
> YJ is different but my 76 CJ has square pieces of plate steel that the
bolt
> goes into. I thought they were the same. There's like a small box that's
> welded over the plates that lets the plates shift a little for adjustment
> but won't let them turn. That's not the case with your YJ?
> Good Luck,
> Jim
> "jdarg" <ruhle@hotmail.com> wrote in message
> news:1Q3Tc.562485$pF1.63416@news.easynews.com...
> > I'm upgrading my crumbling factory mounts to Daystar polys and despite
> > drilling 1/8" holes in the tub and shooting it with PB Blaster for a
week
> I
> > managed to still snap three of the bolts - the two between the front
seats
> > and the rollbar and the rearmost driver side.
> >
> > My plan of attack on the rear mount was to cut an opening in the rear of
> the
> > body large enough to grind off the ears that hold the nut and lift the
> thing
> > out and replace with a standard washer/nut. My passenger side rear mount
> > bolt fell out at some point before I got this Jeep so I had previously
> > slotted that side and used just a regular washer and nut as the factory
> nut
> > had no more thread and I couldn't really tap for the next size up.
> >
> > I thought I may be able to get the rollbar mounts if I drill the bolt
out
> > from both the top and bottom but I ended up snapping off a drill bit in
> the
> > top of one of them - darn! I still have about 2-3" of bolt in there so I
> > can't really go at it from just one end. Should I just not bother and
cut
> > the opening large enough to grind out the ears holding in the nut and do
> the
> > same as in the rear? The bolts seem pretty soft but now that I have a
bit
> > stuck in there it's going to be really rough drilling through that one.
> >
> > Any comments from someone who's been through this? I'd rather not cut up
> the
> > floor more than I have to but I'm afraid I don't have much choice at
this
> > point. Luckily I was able to get all the other bolts out relatively
> easily.
> >
> > -jd
> >
> > '94 YJ
> >
> >
>
>

 

I had a similar problem last winter installing a 1" MORE body lift on my 94
YJ. The rear left snapped lust like yours, I did the same thing with a bolt
& washr. However, I couldn't get the old square captive nut for the mount
out, so I just drove it up into the rear crossmember and stuck it inplace
with some body sealer.

Even thougfh I'd done as you (without the extra holes) and soaked the bolts
down with PB Blaster I had one of the main bolts come out with the threads.
I insalled a helicoil and reinstalled all new factory hardware. So far, so
good.

In your case I'd just bitethe bullet and cut in from the top with a hole saw
which you can follow with a metal or rubber plug. This is a comon problem
with SWB Jeeps that have spent time in road salted areas or along the
coasts.


"Drink" <drink@gnt.net> wrote in message
news:cglhqh$8rf$1@news.utelfla.com...
> Had a related problem yesterday. Trying to get the bolts out, the
plates
> rotated and just ripped the box that holds them in place. Not sure if
your
> YJ is different but my 76 CJ has square pieces of plate steel that the
bolt
> goes into. I thought they were the same. There's like a small box that's
> welded over the plates that lets the plates shift a little for adjustment
> but won't let them turn. That's not the case with your YJ?
> Good Luck,
> Jim
> "jdarg" <ruhle@hotmail.com> wrote in message
> news:1Q3Tc.562485$pF1.63416@news.easynews.com...
> > I'm upgrading my crumbling factory mounts to Daystar polys and despite
> > drilling 1/8" holes in the tub and shooting it with PB Blaster for a
week
> I
> > managed to still snap three of the bolts - the two between the front
seats
> > and the rollbar and the rearmost driver side.
> >
> > My plan of attack on the rear mount was to cut an opening in the rear of
> the
> > body large enough to grind off the ears that hold the nut and lift the
> thing
> > out and replace with a standard washer/nut. My passenger side rear mount
> > bolt fell out at some point before I got this Jeep so I had previously
> > slotted that side and used just a regular washer and nut as the factory
> nut
> > had no more thread and I couldn't really tap for the next size up.
> >
> > I thought I may be able to get the rollbar mounts if I drill the bolt
out
> > from both the top and bottom but I ended up snapping off a drill bit in
> the
> > top of one of them - darn! I still have about 2-3" of bolt in there so I
> > can't really go at it from just one end. Should I just not bother and
cut
> > the opening large enough to grind out the ears holding in the nut and do
> the
> > same as in the rear? The bolts seem pretty soft but now that I have a
bit
> > stuck in there it's going to be really rough drilling through that one.
> >
> > Any comments from someone who's been through this? I'd rather not cut up
> the
> > floor more than I have to but I'm afraid I don't have much choice at
this
> > point. Luckily I was able to get all the other bolts out relatively
> easily.
> >
> > -jd
> >
> > '94 YJ
> >
> >
>
>