Sold my FJ40 and started building my FZJ80 because I wanted nice "bolt-on" intalls, rather than fab and weld.. GRRRRR!! While installling my 3" heavies I followed the book, a weeks worth of PB Blaster and gentle but constant pressure on the rear lower shock bolts, with a breaker bar. Heat, cool, heat cool.... etc. Spent 2 hours trying to nurse the first one off.. SNAP!! Broke off flush. Then I moved to the other side, spent about an hour... SNAP!! GRRRR!! First bright idea was to drill it out and try a big arse Ez-Out... Wouldn't budge, so I decided since I already had it drilled out to 5/16" I would just tap it 3/8-nc and stick a bolt in it.... guess what the tap did... SNAP!! Spent about an hour trying to get the tap out, which also broke off flush.
So, now I'm days into this 3 hour job and searched the forum to the point that I know everyone on here who has an 80!! Came across one suggestion that I should've thought of in the first place, but welding was so far outta my mind for this "bolt-on" mod, that it eluded me. Can't find the thread now, or remember who posted the idea but Mega kudos!!!! Here it is, go to Lowe's / Home Depot, whatever, and get two 12mm/1.25x30 bolts and lock nuts, saw the bolts off to the proper length and weld 'em to the ends of the shock mounts, problem solved. Use the 12mm bolt in the event that it snapped off far enough inside the boss that you can start the threads to make your welding easier.
My 2 cents worth... If you have a welder snap those SOB's right off in 7.3 seconds, weld a stud on the end of each in 5 minutes and be the hell done with it!!!
Also, for the DS top shock bolt (under the master cylinder) I used this raggedy "gear wrench-ratchet" set that I got from NAPA, that I always hated, but it's the solution to that particular situation. the whole set is like $34 at NAPA on sale. no affiliation, just glad I found a use for that POS ratchet set that I've cursed for years!!
So, now I'm days into this 3 hour job and searched the forum to the point that I know everyone on here who has an 80!! Came across one suggestion that I should've thought of in the first place, but welding was so far outta my mind for this "bolt-on" mod, that it eluded me. Can't find the thread now, or remember who posted the idea but Mega kudos!!!! Here it is, go to Lowe's / Home Depot, whatever, and get two 12mm/1.25x30 bolts and lock nuts, saw the bolts off to the proper length and weld 'em to the ends of the shock mounts, problem solved. Use the 12mm bolt in the event that it snapped off far enough inside the boss that you can start the threads to make your welding easier.
My 2 cents worth... If you have a welder snap those SOB's right off in 7.3 seconds, weld a stud on the end of each in 5 minutes and be the hell done with it!!!
Also, for the DS top shock bolt (under the master cylinder) I used this raggedy "gear wrench-ratchet" set that I got from NAPA, that I always hated, but it's the solution to that particular situation. the whole set is like $34 at NAPA on sale. no affiliation, just glad I found a use for that POS ratchet set that I've cursed for years!!
