WELD nuts, what are folks doing to repair or replace

[Singha]

Ok it's been 3+years since I first experiance my first weld nut breaking loose from the welds.

So some are not sure what weld nuts are. These are the nut that are spot (poorly) welded in the frame. So certain things can be bolted to the frame. Like sway bar mounts (my first one that broke 3years ago from poor welding penetration), slider bolts.
Now my buddy's 08 the sliders weld nut are snapping off (4 off them).

what are folks doing to fix the broken ones.
Hate to drill holes all over the frame on the back side to get a wrench and nut in there.

 

[NCFJ]

The weld nuts are a 4 sided nut that is spot welded on the 4 corners, an you are correct that they are poorly welded at best. Dut to the fact that I am constantly taking my bumpers on and off to build bumpers for customers all of my weld nuts for the bumpers have popped off.

I have gone back and welded new nuts back in their place, which for me is not that much of an issue, but if you do not weld you will have to have someone else do it for you. Most are a PIA to get to as well. I wish I knew an easy answer.

 

[BMThiker]

It is an issue that bears some thought. I have re-engineered my middle skid to use the bolt holes that once held my Cat protection bars, because the other weldnuts in the trans cross member popped loose. Now my frame rail (cat protection) weldnuts are starting to go too. Three of the six weldnuts that hold the front skid are gone and my front skid is now a little droopy. Most of these locations are damn near impossible to fix (reweld) without cutting further into the frame.

I keep going back to a proverb I once saw at an offroad event: bolt-on is for beginners. Many of us started off as beginners, but are no more. I had my sliders welded on when my fender tubes got installed. Thinking I may do the same for other elements, but not the skids. I just need to design an attachment method that is not as vulnerable as the weldnuts. If there is enough space, I like the method BUD used for the transition from the mid skid to the gas skid - a tubular brace that does not stress the weldnuts as much upon impact.

 

[NCFJ]

You make a very good point Rick. The "bolt on is for beginers" phrase is the standard among many old timers and hard core wheelers. When it comes to skids this is not true as they need to come off to service the rig. Unfortunately the weld nuts on most rigs, FJs included are a weak link.

Manufacturers of aftermarket products such as skids and sliders use the weld nuts because 99% of their customer base do not want to go to the trouble and expense of having proper hardware installed, such as drilling into the frame etc. But after a time the weld nuts prove to not be up to the task at hand and let go, leaving the vehicle owner to now go back and re engineer a fastening method.

 

[4Rocker]

I have had good luck using M8x1.25 stainless steel rivnuts from McMaster-Carr to replace some of the frame crossmember nuts that broke loose for my skids. This way, rather than loading the weak factory welds in tension, the rivnut is pressed against the frame in compression.