Stripped welded in nut in frame - best repair option?

[ihadmail]

I stripped the front differential front mounting nut last night when installing my diff drop kit. It's bad. At least half of the threads came out.

I was able to get it limpable by running a 7/16" grade 8 up through the center of the welded in nut. It's no fun trying to get a loose nut on top of that welded nut, I wouldn't wish that on anyone.

I have ordered the correct size helicoil kit. I am not sure this is the best solution though since that welded nut doesn't have a ton of material to be drilling/tapping/inserting helicoil into.

I have a welder, but again I'm not sure that simply welding a plate to the outside of the frame there and then drilling/tapping it will be sufficient either. Anyone have experience with such things? Any ideas that I haven't already mentioned?

 

[billygoats]

go 1 up in size (i think it is a standard thread pitch) and tap the welded nut. Then get a new bolt that matches the new tapped thread.

 

[Fast Eddy]

Weld it up solid, then redrill and retap it.

 

[reznunt]

I'd do what billygoats said, tap a larger size, if possible. It's a little less work than weld/drill/tap. Either would work though.

 

[ihadmail]

I got my helicoil kit in today and compared it to another one of the same sized nuts on the diff mounts. I stayed laying under the truck looking at it for a while, and contemplating what I was going to do. I have decided to refrain from trying to weld the entire hole closed and drill/tap it. The top of that nut is so far away from the outside of the frame I'm afraid I can't get good penetration throughout the weld and definitely can't see what I'm doing while welding it with my MIG gun.

If drilling/tapping/helicoil installation doesn't work for me then I will take more drastic measures to properly get this fixed. Thanks all for your input.