Header Panel Studs

[acfortier]

It seems that I'm missing (sort of) two of the 4 studs that are used to hold the header panel to the body. The top one on the driver's side is missing, and the bottom one was replaced by a normal bolt, but you'd have to get a socket on it from inside the wheel well in order to tighten it... kinda a pain.

 

What's the best way for me to get replacement bolt/studs in the two holes without welding?

 

Pic of issue:

 

 

Pic of good side:

 

[eaglescout526]

I don’t see any thing in the catalog. 
 

May not be serviceable. 

[acfortier]

Yeah, I’m thinking this is going to be a creative solution.

 

I wonder if I could precisely cut out a square for a carriage bolt? Not even sure what tool I’d use to do that. I guess that would only work for the top—bottom hole is already too big. JB weld a bolt to the inner fender so that the stud sticks out?

[eaglescout526]

Well here's an idea. If you can get up in there, see if you can find the same thread pitch bolt, flatten the hex end and weld it to the fender frame so that way it never moves again. 

[acfortier]

I want to avoid welding if possible—I think it’s too tight of a space to be able to do that. And welding is a pain, haha.

[Strokermjcomanche]

You can use this and then bolt it on 

 

 

[acfortier]

Ooo that would definitely work for the upper one. The lower hole might be too big… I’d have to check it.

 

[Strokermjcomanche]

1 hour ago, acfortier said:

Ooo that would definitely work for the upper one. The lower hole might be too big… I’d have to check it.

 

Use washers if the hole is too big 

[acfortier]

28 minutes ago, Strokermjcomanche said:

Use washers if the hole is too big 

With the nutsert tool?

[Strokermjcomanche]

27 minutes ago, acfortier said:

With the nutsert tool?

Yes , One washer on each side of the fender. Then you put the nut CERT insert through the washers and  it’ll squeeze everything together. 

[watchamakalit]

Why not just replace the fender, and repaint the whole truck?

[acfortier]

48 minutes ago, watchamakalit said:

Why not just replace the fender, and repaint the whole truck?

That’s definitely crossed my mind… I’m not sure if the new fenders come with the studs haha

[watchamakalit]

I am pretty sure that stud is part of the fender.  I think the nutsert idea is a good one. 

[Minuit]

I'm also pretty sure that the stud is part of the fender, either pressed or tacked into it from the other side. Sadly, finding a fender in that color is going to be next to impossible.

 

I'd use the threaded insert tool. They're useful for all kinds of things too, so you'll find something else to use it for.

[acfortier]

Yep, picked up the nicer one from Harbor Freight (https://www.harborfreight.com/10-in-professional-rivet-nut-setter-kit-58078.html) as it already included larger rivnuts. Haven't gotten a chance to tackle this yet, but I think the M8 size might be big enough to fit in the large oval hole.

[dasbulliwagen]

They changed the style of the header panel mounting between 86 and 87. I found this out when installing an 86 Wagoneer header panel on my 87 Comanche. I think the earlier one has the bolts on the header panel and the later ones have studs on the fender, so bolting through and tightening down from the inside is an option. 

[mjeff87]

I seem to remember when I took my header panel off on my 87 that I had a bolt/stud combo on each side.  I know everything was OEM, so maybe that's normal?  I do remember it being a total PITA to get the upper stud and/or nut undone.