I have posted so many "help" requests in the past that I thought I'd create one thread for all my woes.
I am still rehabbing my rust-affected FJ-80 and running into challenges as I go. The latest installment is breaking off a bolt on the fuel filler tube brace. This darned thing sits right behind a frame brace and there is no way to get to it. I tried welding a nut to the Japanesium bolt. Which broke off. I tried to drill a hole in the bolt through a hole in the frame brace. I could only get access via a long drill bit (any normal ones didn't reach) and it went off-center. Welded more nuts. MANY. Even welded a hex wrench to it to see if it will fit. You cant really reach back in there, but I tried my best. They all broke off.
I am considering the following:
1) Just put one bolt in there. REJECTED
2) Cuss and walk away from it for a bit. DONE
3) Cut a square piece out of the mount point (all the way around), add a weld-nut to it and weld it back in. - There is no way to get a tool in there for the cutting.
4) Cut a hole from inside the cabin and come at it from the top. LAST RESORT
Those bolts might break easily, but boy can they rust-weld into a nut! Better than an actual weld.
Any other thoughts? I can imagine that getting a tap in there would be great fun also.
I am still rehabbing my rust-affected FJ-80 and running into challenges as I go. The latest installment is breaking off a bolt on the fuel filler tube brace. This darned thing sits right behind a frame brace and there is no way to get to it. I tried welding a nut to the Japanesium bolt. Which broke off. I tried to drill a hole in the bolt through a hole in the frame brace. I could only get access via a long drill bit (any normal ones didn't reach) and it went off-center. Welded more nuts. MANY. Even welded a hex wrench to it to see if it will fit. You cant really reach back in there, but I tried my best. They all broke off.
I am considering the following:
1) Just put one bolt in there. REJECTED
2) Cuss and walk away from it for a bit. DONE
3) Cut a square piece out of the mount point (all the way around), add a weld-nut to it and weld it back in. - There is no way to get a tool in there for the cutting.
4) Cut a hole from inside the cabin and come at it from the top. LAST RESORT
Those bolts might break easily, but boy can they rust-weld into a nut! Better than an actual weld.
Any other thoughts? I can imagine that getting a tap in there would be great fun also.
Last edited: