1973-ish FJ40 Ulele (u-LAY-lee)

[visike]

In the depths of a project to make the old fj40 my grandpa bought drivable again.

Question 1) I'm redoing the struts for the rear hatch door and the dang bolts are loose in whatever backing holds them in place (see pictures). I can't seem to get a hold of the bolt shanks after grinding the heads off to pull them out, and even when I could grab a hold of them they just spin.
What does one do to extract these bad boys? I have the strut ready to put in again, but I need something to attach them to. I imagine, in the worst case, I have to use a dremel to saw out a rectangle and possible weld in a patch with thick metal threaded to hold in the new bolts. I'd prefer to avoid that but it just might be what I have to do.

 

[timmyisinthewell]

There shouldn't be anything spinning there other than the bolts themselves. There is a tapped plate spot welded to the inside structure. Can you not drill the broken bolt pieces out?

 

[charliemeyer007]

Maybe the threads are stripped enough to just spin but not pull out. Try drilling them out. if they just spin then try punching them threw. If that doesn't work, a couple drop of superglue with a few hours to dry - then try drilling them again. Rivet nuts come in all sizes. You can set them without the special tool if you are just doing a few.

Maybe drilling the whole unit out to say 7/16. Tap and screw in a section of bolt. Use strong thread locker to lock it in place. Drill and tap the stub for factory thread.

 

[visike]

Isn't the strongest but I drilled the bolts out, and then tapped new holes - if these slip I'll go one size up.
I'm thrilled because we've fought this losing fight for 30+ years. Today, it can hold up it's own rear window.

 

[pb4ugo]

Did you put a gas strut in the tubes?
Looks good

 

[visike]

Did you put a gas strut in the tubes?
Looks good

No, PB, it's an old replacement - can you link the gas tube? I'd do it if these struts lose their spring.

 

[Engineer8000]

you are not qualified to go anywhere near this truck.

 

[pb4ugo]

No, PB, it's an old replacement - can you link the gas tube? I'd do it if these struts lose their spring.

I haven't run a top in decades, so it's not a priority. I know It been done and not uncommon. The info is somewhere within this site.

Looks like a nice 40.