Builds Helga: 1966 FJ40 FST

[middlecalf]

No perfection here but if there’s a bit of the bolt showing above the surface I drill a small dimple in the top of what’s left (mostly to get to “good” steel in the bolt) then weld a close fitting nut on that nub, not being afraid of heat (aka turn the bolt remnant red). Then crank on the nut - the heat does a lot of the work. If that fails, more cussing. Then…. drill the whole thing out and retap.

 

[tahoe40/45]

If there is no broken bolt above the surface, try starting with a small drill bit, center it as best as possible onto broken bolt, then drill all the way through if you can. Then move to the next size drill bit and repeat.
Do this until you are one or two size drill bits below the recommended drill bit size to retap. ( if your hole is off center stop before you hit the threads of the capture nut or what ever the bolt is going into)
At this point you might be able to punch the remaining bolt out with a thin metal punch tool. ( like one in photo) Be carful not to punch out capture nut or backing plate.
If your hole is centered pretty good you can also go all the way up to the recommended drill bit size for retapping, then get the tap to force out remaining threads.
This has worked for me many times.
The threads may become a little stretched after all that. I have fixed that by forcing some JB weld into threads, let it harden then retap threads.

I hope all that isn't too confusing.

 

[KennyBob]

Thanks gents! I have attempted most of that to varying degrees of success. I do need to bite the bullet and invest in a welder.

 

[KennyBob]

Alright. Upholstery noob here. How does one attach the vinyl AND the back plate on the seat backs? I assume they both use the same screw holes in the frame but I don’t see how.

 

[KennyBob]

Sometimes you just need to do it and quit thinking about doing it. One down, seven to go.

 

[tucker74]

Looking good! Pretty soon you'll be able to sit in it and make vroom-vroom noises

 

[KennyBob]

Looking good! Pretty soon you'll be able to sit in it and make vroom-vroom noises

I do that already! Now it’ll be in comfort and style.

 

[KennyBob]

When life gives you broken bolts, try welding nuts on, then try drilling them out, then just weld on new threads.

Disassembled, cleaned and applied rust converter the drivers and jump seats.

Also finished the passenger seat! Do y’all think I need to pull the vinyl tighter to the frame?

 

[EWheeler]

When life gives you broken bolts, try welding nuts on, then try drilling them out, then just weld on new threads.

View attachment 2897241
View attachment 2897242
Disassembled, cleaned and applied rust converter the drivers and jump seats.

View attachment 2897243

View attachment 2897244
Also finished the passenger seat! Do y’all think I need to pull the vinyl tighter to the frame?
View attachment 2897245

Looks great man! Did you end up buying and installing the SOR foam? Any feedback on that stuff?

 

[KennyBob]

I did indeed. It’s nice I suppose. I don’t have anything to compare it to honestly. The only negative I can think of is that the foam doesn’t taper on the sides like the spring frames do. The foam are all rectangles and the spring frames are more of a trapezoid. Everything still fits well enough though. It’s nicer than cutting my own foam for sure.

 

[HelloKitty65]

No worries. I’m used to it by now.

Open to any advice on broken bolt removal. I have not yet perfected that art.

Prevention? Know the smoke wrench trick?

 

[KennyBob]

Prevention? Know the smoke wrench trick?

I do not.

 

[HelloKitty65]

Mark calls it that. Heat it up with a torch. Good and hot. After it cools, PB Blaster.
Not good for patina painted places you want to save, but good elsewhere.

 

[KennyBob]

All seats done! Pictures of jump seats to follow.

 

[EWheeler]

All seats done! Pictures of jump seats to follow.
View attachment 2904623

Those look great!

 

[KennyBob]

Those look great!

Thanks! There’s a few things I’d like to change if I can find the time/energy. I.e. how they look like I need to take more slack out of the covers in some places. I’m wondering if that’s a function of Cruiser Corps covers with SOR foam…But it feels good to have them all done. Still need to extract one bolt from the floor for the passenger seat though.

 

[tucker74]

A few months and none of those little things will bother you . Get the jump seats done too? What’s left before you can take her around the block?

Tucker

 

[Chuckha62]

Thanks! There’s a few things I’d like to change if I can find the time/energy. I.e. how they look like I need to take more slack out of the covers in some places. I’m wondering if that’s a function of Cruiser Corps covers with SOR foam…But it feels good to have them all done. Still need to extract one bolt from the floor for the passenger seat though.

Ordinarily with upholstery, the pad/foam is just a base. Typically, batting material (either cotton or synthetic) is used on top of the foam, directly under the upholstery material. If you haven’t used any batting, that would explain loose fitting covers.

 

[KennyBob]

Hmm. I haven’t used anything else but the covers do have a relatively thin layer of something sewn into them on the tops. Happen to have a picture or example of batting?

The problem I think I’m (also) having is that the cutouts for the legs seem too far away from the legs. At least for the front seats (passenger particularly). Almost as if the springs aren’t compressed enough. Other than that the fronts seem fine. See attached picture.

 

[KennyBob]

Here’s the jump seats:

I can see the jump seats definitely needing a layer of “batting”.