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Old 09-30-2022, 10:35 PM #16
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I replaced my tank straps over the weekend and sheared off the bolts in the process despite my efforts to loosen them carefully.
I then used a punch and a large hammer to knock the sheared bolt and nut free inside the frame rail after reverse drill bits and easy outs failed.

As you can access the location via openings in the frame I used a magnetic pick up tool to align new hardware (fender washer + nylon nut + bolt) for the new strap.
I will be doing the same operation for all of the tank skid bolts I sheared off as well.
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This is what I did. Couple whacks with the BFH and a punch and the tack welded nut was gone. Dropped a long bolt through the hole from the inside with a magnetic pickup tool. Attached the strap with a nut and cut off the excess. The rear one was much harder for me as the metal was rusted enough that it broke off the tab. That one took welding.

I plan on doing what you both did and just knocking out that weld nut, do you mind linking me to a similar punch you guys used? The ones I have now are smaller ones and would not work.
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Old 10-01-2022, 08:15 PM #17
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I plan on doing what you both did and just knocking out that weld nut, do you mind linking me to a similar punch you guys used? The ones I have now are smaller ones and would not work.
The Mayhew set sold at Home Depot is good quality and is (or was) made in the USA. You can also cut or drill hardened steel with carbide, I've only used it in die grinders but they do make carbide drill bits.
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Old 10-01-2022, 11:03 PM #18
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The Mayhew set sold at Home Depot is good quality and is (or was) made in the USA. You can also cut or drill hardened steel with carbide, I've only used it in die grinders but they do make carbide drill bits.
Yeah, drilling it out with a carbide bit was another option I had in mind, but knocking out the weld nut is probably the simplest now. I actually thought of buying a longer air hammer chisel bit instead, probably will be a lot easier than a punch with hammer given the awkward angle you'd have to hit at.
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Old 10-04-2022, 03:51 PM #19
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Originally Posted by gookies View Post
I plan on doing what you both did and just knocking out that weld nut, do you mind linking me to a similar punch you guys used? The ones I have now are smaller ones and would not work.
I have a set like in the link below. Probably would use one of the large lower middle punches like the 5/16 or 3/8. If I didn't have this I'd use whatever I had on hand that was small enough to fit through the hole and drive with some oomph. 3/8 round stock would work or an old thick-ish screwdriver.

Amazon.com: ATD Tools 729 29-Piece Punch and Chisel Set : Tools & Home Improvement
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Last edited by MikeinNH67; 10-05-2022 at 03:44 PM.
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Old 10-21-2022, 06:56 PM #20
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Wanted to provide an update on this, I ended up going with the above solution, knocking out the welded nut. I purchased an inexpensive 12 pc. chisel set from Harbor Freight and a few whacks with a 3 lb hammer, the welded nut came loose. The frame hole I used to get the best angle was the large circular one to the bottom right of the rectangular one and I had a flexible magnetic pick up tool to retrieve it. I plan on using the same tool in order to position the new nut inside the frame.

For those who end up changing their gas tank straps and would like to avoid breaking bolts, I suggested in the sticky (gas tank strap sticky), to see if the pin could be knocked out of the buckle instead, then you could use a similar set-up as on the other side to re-install (pin + clip). Or if you end up breaking this same bolt, don't bother trying to extract it, just knock it out; I wasted some time trying to extract it (did not realize the only threaded portion was the welded nut, which makes knocking it out very easy).

Also, the torque specs for both tank strap bolts is 30 ft/lbs. For installation, I ended up using a 12mm ratcheting wrench with a flex head to hold the nut inside the frame in place while tightening. To initially position it, I stuck a screwdriver in the hole and then dropped the nut over that to guide it in place.


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Last edited by gookies; 10-22-2022 at 02:18 PM.
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