dagr8tim
09-26-2011, 10:45 PM
I did this awhile back and thought I would share.
I snapped 2 of the bumpstop bolts when I was changing them. For the short term I punched the studs and the fastener into the subframe and threaded in some half inch bolts. I wasn't too happy with that solution because I felt they wouldn't be strong enough. While reading JeepForum, I came across a thread on fixing TJ transfer skid plates (http://www.jeepforum.com/forum/f9/nutsert-transfer-case-removal-install-390635/). I figured if it would work for a skid plate, it would work for a bumpstop. I wasn't about to spend $8 a pop on them from a dealership, and I knew I didn't need that much toughness. I found some nutserts at Fastenal (http://www.fastenal.com/web/products/detail.ex?sku=0125658&ucst=t) that would fit the holes in my subframe and should hold. I got 4 of them with tax and shipping for less than $9.
http://buckeyejeeps.com/albums/nutsert/Netsert_Tool_800x598.sized.jpg
Here's a nutsert on a homebrew installation tool. It's an M10 bolt with 2 flat washers, a 7/16 nut (anything large enough to spin freely on the bolt will work), and a star lock washer.
http://buckeyejeeps.com/albums/nutsert/Installation_Tools_800x598.sized.jpg
The only hand tools needed are a socket to turn the bolt, and a wrench to hold the nut from spinning.
http://buckeyejeeps.com/albums/nutsert/Nutsert_Installed_01_800x598.sized.jpg
Test Installation on one of the doors of my parts XJ. I wanted to see exactly how it installed before I got up under the Jeep where space was limited.
http://buckeyejeeps.com/albums/nutsert/Nutsert_Installed_02_800x598.sized.jpg
Cross section of the installation. The door panel wasn't vertical and was dented, so the bolt's not straight.
http://buckeyejeeps.com/albums/nutsert/Subframe_Nutsert_Installed_800x598.sized.jpg
Both nutserts installed in the frame.
http://buckeyejeeps.com/albums/nutsert/Bumpstop_Installed_800x598.sized.jpg
Bumpstop installed.
Here are some more random pics (http://buckeyejeeps.com/gallery/nutsert) of took while I was working on this project. If the fix seems to hold up, I may invest in a hand full of these when I replace my rear shocks next time. I will also be using these to install my factory TC skid plate. I would have used them on my front end skid plate if I would have known about them back then.
I snapped 2 of the bumpstop bolts when I was changing them. For the short term I punched the studs and the fastener into the subframe and threaded in some half inch bolts. I wasn't too happy with that solution because I felt they wouldn't be strong enough. While reading JeepForum, I came across a thread on fixing TJ transfer skid plates (http://www.jeepforum.com/forum/f9/nutsert-transfer-case-removal-install-390635/). I figured if it would work for a skid plate, it would work for a bumpstop. I wasn't about to spend $8 a pop on them from a dealership, and I knew I didn't need that much toughness. I found some nutserts at Fastenal (http://www.fastenal.com/web/products/detail.ex?sku=0125658&ucst=t) that would fit the holes in my subframe and should hold. I got 4 of them with tax and shipping for less than $9.
http://buckeyejeeps.com/albums/nutsert/Netsert_Tool_800x598.sized.jpg
Here's a nutsert on a homebrew installation tool. It's an M10 bolt with 2 flat washers, a 7/16 nut (anything large enough to spin freely on the bolt will work), and a star lock washer.
http://buckeyejeeps.com/albums/nutsert/Installation_Tools_800x598.sized.jpg
The only hand tools needed are a socket to turn the bolt, and a wrench to hold the nut from spinning.
http://buckeyejeeps.com/albums/nutsert/Nutsert_Installed_01_800x598.sized.jpg
Test Installation on one of the doors of my parts XJ. I wanted to see exactly how it installed before I got up under the Jeep where space was limited.
http://buckeyejeeps.com/albums/nutsert/Nutsert_Installed_02_800x598.sized.jpg
Cross section of the installation. The door panel wasn't vertical and was dented, so the bolt's not straight.
http://buckeyejeeps.com/albums/nutsert/Subframe_Nutsert_Installed_800x598.sized.jpg
Both nutserts installed in the frame.
http://buckeyejeeps.com/albums/nutsert/Bumpstop_Installed_800x598.sized.jpg
Bumpstop installed.
Here are some more random pics (http://buckeyejeeps.com/gallery/nutsert) of took while I was working on this project. If the fix seems to hold up, I may invest in a hand full of these when I replace my rear shocks next time. I will also be using these to install my factory TC skid plate. I would have used them on my front end skid plate if I would have known about them back then.