Why are the simple things so complicated??

[Dino]

Reluctantly I spend the 40 + bucks so I could mount the $25 70 and up voltage regulator.  Somewhere down the line, a race only vr was mounted to the firewall which I only recently found out.

Turns out that the two holes that are supposed to hold the bracket have been drilled so now the bolts don't fit.  I thought I could make it work by slightly enlarging the holes in the bracket but the body bolts won't grab anough and I'm not willing to drill the bracket again.

A good way to fix this is either hammering the metal with a ball peen hammer and a dolly behind it so the holes get smaller, but with the a/c in place, I don't have the needed access behind the holes.

The best way of course is to weld the holes shut with a brass spoon behind it and then re-drill them, but that means tearing down half the dash and I'm not up for that.

I can repair this properly when the time comes to redo the whole car, but for now I need a way to secure the bracket to the firewall.

Any ideas?

[Tilar]

Can you get to it at all from the inside? oops, never mind, I just saw where you said you didn't have the needed access behind it.

[Dino]

Well I can get there...but barely.

Looking through the glove box (with lines removed of course) I can see the bottom hole and I 'may' be able to reach it.  But the top hole is much harder to reach.  I can probably get something back there but I won't have the ability to put force behind it.

I even tried accessing through the big hole where the heater valve goes but I run the risk of damaging the A/C tubing and whatever else is back there.

I have to admit, this would've been easier with the car on the ground instead of 2 feet up on stands.   

[Ghoste]

Do you have any friends who are built like a spider monkey?

[Dino]

Do you have any friends who are built like a spider monkey?

Not since I told them they're built like spider monkeys no.   

[6pkrtse]

Reluctantly I spend the 40 + bucks so I could mount the $25 70 and up voltage regulator.  Somewhere down the line, a race only vr was mounted to the firewall which I only recently found out.

Turns out that the two holes that are supposed to hold the bracket have been drilled so now the bolts don't fit.  I thought I could make it work by slightly enlarging the holes in the bracket but the body bolts won't grab anough and I'm not willing to drill the bracket again.

A good way to fix this is either hammering the metal with a ball peen hammer and a dolly behind it so the holes get smaller, but with the a/c in place, I don't have the needed access behind the holes.

The best way of course is to weld the holes shut with a brass spoon behind it and then re-drill them, but that means tearing down half the dash and I'm not up for that.

I can repair this properly when the time comes to redo the whole car, but for now I need a way to secure the bracket to the firewall.

Any ideas?

You could always add a nut sert into the hole & a threaded bolt. I use my nut sert tool all over our race cars. Makes for mounting & installing anything anywhere in sheet metal a one person job. No second person needed to hold the nut on the back side anywhere. LOL

[ODZKing]

Not since I told them they're built like spider monkeys no.   

I ran into this with my 73 a lot. BUt I found similar if not the same head screws only different thread or a bit larger to solve most of the issues. How big are the holes, way bigger than that I am assuming? 

[twodko]

Are rivets an option here Dino?

[twodko]

Are rivets an option here Dino?

[twodko]

For some reason I'm duplicate posting.....sorry. It's gotta be those damn adult sites.

[Dino]

The nut sert thing would work but I don't have the tool.  I'll have to look into renting one from the local auto parts stores.

The bolts I tried are one size bigger than the stock bolts.  The holes are just a tad too big for the bolts, at first I thought they would fit but they wouldn't tighten.

Rivets could work I suppose, I should have no issue with clearance in the back.  I'll have to look into that this evening and see what kinds of rivets I have.

What about one of those nuts you stick through the bracket and firewall that squish when you tighten them?  I'm thinking of the kind you would use on drywall.  Anything like that available for sheet metal?

[Dino]

For some reason I'm duplicate posting.....sorry. It's gotta be those damn adult sites.

What are you talking about?

[Dino]

For some reason I'm duplicate posting.....sorry. It's gotta be those damn adult sites.

What are you talking about?

[Dino]

 

[cdr]

What about one of those nuts you stick through the bracket and firewall that squish when you tighten them?  I'm thinking of the kind you would use on drywall.  Anything like that available for sheet metal?

yes the have them at hardware store,they are similar to the nut sert but are a softer steel.

[Dino]

Great!  I'll try to find those before I do anything else.

Thanks 

[b5blue]

Look just hog the hole till it fits a license plate nut, the square white things that snap into your bumper. 

[Troy]

If you're gonna weld at some point just drill 2 new holes or use self drilling sheet metal screws. It seems like a popular choice of previous owners of my cars!

Troy

[ODZKing]

How about something like this ... I believe it is called a rivet nut.
http://www.traderscity.com/board/products-1/offers-to-sell-and-export-1/flat-head-full-hex-rivet-nut-fastener-hex-rivet-nut-141109/

[6pkrtse]

The nut sert thing would work but I don't have the tool.  I'll have to look into renting one from the local auto parts stores.

The bolts I tried are one size bigger than the stock bolts.  The holes are just a tad too big for the bolts, at first I thought they would fit but they wouldn't tighten.

Rivets could work I suppose, I should have no issue with clearance in the back.  I'll have to look into that this evening and see what kinds of rivets I have.

What about one of those nuts you stick through the bracket and firewall that squish when you tighten them?  I'm thinking of the kind you would use on drywall.  Anything like that available for sheet metal?

Dino,
Your are in Michigan too, correct? You could borrow my nut sert tool some time if needed from one Charger dude to another.

[bull]

Are those 5/16" holes? Can't recall but it sounds right. You could always bump them up to the next larger size and get a pair of the larger, correct-looking anchor head body bolts (3/8"?) to mount it. 99% of the people looking wouldn't know the difference, if that matters.

[Dino]

I'm unsure what size the stock ones are.  The holes in the bracket are pretty close to the bent edges.  The bracket has a 'U' shape to it.  One size over stock bolts would work but barely as the head will touch the side of the bracket.  I would need a bolt that is two sizes bigger than the stock bolt but have a small head.  I've never seen any like that before. 

How about something like this ... I believe it is called a rivet nut.
http://www.traderscity.com/board/products-1/offers-to-sell-and-export-1/flat-head-full-hex-rivet-nut-fastener-hex-rivet-nut-141109/

That may work as long as it doesn't spin in the hole.  A bit of RTV would keep it in place though.

Dino,
Your are in Michigan too, correct? You could borrow my nut sert tool some time if needed from one Charger dude to another.

Yes I am and thank you for the offer!  I will try a few things suggested here but I may take you up on that offer.      


Thanks for the help fellas!   

[bull]

Which bracket are you using? Do you have a pic?

[6pkrtse]

Rivet nut is the same thing as the nut sert tool kit I have. Same thing just different brand names.

[Dino]

Rivet nut is the same thing as the nut sert tool kit I have. Same thing just different brand names.

Good to know, thanks!

Which bracket are you using? Do you have a pic?

That's the one.

http://www.billrolikenterprises.com/proddetail.asp?prod=2926621-P