Rawlnuts aka well nuts For roof rack holes

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It looked like that might happen. I know the pieces of filler rod that stuck down too far were not very long. Unfortunately, I was not the one to have to cut them out from the inside so I never got a good look at the tolerance.
 
So the shorter one does miss the sunroof? Or is it a problem to remove and replace if it is the wrong size? I welded some of these shut on a friends truck and a little weld rod stuck in too far and kept the sunroof from closing once opened. Easy fix without the liner out but I don’t want to run into that problem with my new truck. I plan on keeping the liner in on this one. I got really lucky I guess with my first truck when i silicon bronze welded my holes shut without removing the liner. I have since learned I almost burned my truck to a crisp. I am bolting these new ones but want to use the right size for the sunroof. Also, if I drill out the nuts from the outside, is there a chance they could get into the sunroof mechanism or just rattle around in there or do they just quietly go away??

yes the shorter wellnuts missed the sunroof when it went back and you will want to make sure your bolt hardware does too since it protrudes past the threaded section as it sucks it in and expands the rubber. zero problem with removing at a later date.... just unscrew and it relaxes and pulls out. ive replaced one or two that I overtightened stressing the rubber to the point of cracking.
 
I feel like this is more simple than its being made out to be...

I and several other locals have simply used half inch long Phillips head screws of the appropriate thread pitch and diameter, and have smeared a bit of clear silicone sealant on the threads before install, and have had zero leaks for somewhere between three amd five years (them) and about a year (me). :meh:
 
I feel like this is more simple than its being made out to be...

You are most likely right. I work in special effects in Atlanta and my boss always tells me to make sure we don't get too complicated if we can pull it with a string or push it with a stick. I still like the idea of the rawlnuts though. Good to know it will work. Easy enough too. Something I read earlier, not sure if it was this thread, but something about using Silicon and corrosion. You have not noticed any rusting where you used the silicon on the hole?
 
Something I read earlier, not sure if it was this thread, but something about using Silicon and corrosion. You have not noticed any rusting where you used the silicon on the hole?

I can't speak for the others, but I used a non-corrosive silicone sealer called Sikaflex.
 
Removed my rack today. Had two nuts spin on me... But, here's some pics to help out... This is a bit of a temp fix until I decide if I wanna do a paint job.

IMG_20181027_154528.webp


IMG_20181027_154546.webp
 
And those bolt lengths do not interfere with the sunroof? I am about to do the same thing in a few days.
 
The sunroof on my '97 opens and closes just fine. No scratches on the glass. I'd use the 12mm. Note that my sealing washers are just galvanized, they didn't have stainless around. I did put a dab of silicone under those, and also around the threads as I snugged them up. I used impact wrench to seat them, then hand tightened.
 
What did you do about the ones that spun? Just cut them off?

Well, one only stripped when i was installing the new screw and washer. The other one didn't really strip, the weldnut basically broke, so I just pulled it up. A bit of a bigger hole, but I sanded down a bit, patched it with a couple layers of foil tape for now.
 

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