How'd you fix the rear? Just drill and tap? I'm gonna take an air hammer to the welded nut and just see if I can use a standard nut/bolt since I really don't want to tap it
It was quite the ordeal... luckily I had a spare bolt laying around that happened to be the right size, thread, pitch, etc.
First I tried this bolt extractor I had, which has a burnishing tool on one end and a reverse-threaded tip on the other end. You use the burnishing tool to drill a hole in the broken bolt then the reverse-threaded end to back the broken bolt out. So I drill the hole with the burnishing tool, heat it up with a propane torch and then use reverse-threaded tip, but that broke off inside the already broken bolt. **** me. Somehow I managed to get the broken piece out of the hole with some gentle persuasion from a chisel and hammer.
So then I found some nice sharp drill bits laying around and drilled a hole straight through the broken bolt using the previously burnished hole as a pilot hole. I didn't' have any drill bits that were large enough though, so I still had a bunch of crap in there from the old broken bolt. I tried to chase out the threads using a tap, but there's not much room to work under the truck so I was using an adjustable wrench to turn the tap. Anyways, the tap then broke off, so I had to spend some time getting that out. All the while I'm trying not to destroy the threads of the existing bolt.
Finally, I say **** it and try just threading the spare bolt into the drilled out hole to see if it would clear out the threads and it worked! I bolted everything back together and was careful not to over-torque in case I had damaged the threads too much.
If I were you, I would either go with your method and remove the welded nut completely, or just drill it out with a bit that is slightly smaller than the nut and use a new bolt to chase the threads. Do not waste time with a screw extractor! I'd even be hesitant to use a tap, although if I had access to a lift and a nice garage I might have been successful without breaking it... It's tough working on your back when its 20 degrees out!