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Old 12-09-2012, 07:56 PM   #1
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badly rusted bump stop bolt question..

im in the process of installing the 2" budget boost kit. apparently you remove the rear upper bump stop cup to install the new spacer..mine is BADLY rusted and surely will break off even with lube,heat..whatever...i did a search but found nothing related to my problem. is it possible to "torch" it out very carefully and just install a bolt? or if my prob is just gonna open a can of worms..i may just leave it stock!! any input is appreciated!

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Old 12-09-2012, 08:10 PM   #2
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just bust it off and drill it out to 7/16". use a new 3/8" or 7/16" grade 8 bolt (whichever fits through your bumpstop extensions), and put a nut + thick grade 8 washer on the top of the rear spring perch. tack weld the washer & nut in place if you have a welder. otherwise you can superglue them together so you can get a wrench on them and get the stuff installed. the rear upper shock mount bolts will probably also break. same deal, drill em out and put new hardware on.

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Old 12-09-2012, 08:25 PM   #3
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i had same problem. i finally said F it and used a 24in pipe wrench to turn the whole bump stop cup to break it off. it ended up knocking alot of the rust off and i was able to unthread the bolt suprisingly.
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Old 12-09-2012, 09:31 PM   #4
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thats good to know..i will bust it off and go with a new bolt then...,i have been cutting and plating the frame,i got this jeep for under 2k and its in great to exc condition as far as cosmetics,but it came from wisconson and is rusty as all underneath.been workin on it an hour or 2 every eve so im gettin closer! already had offers for 3500 for it the way it is..but think ill keep it and have fun!
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Old 12-10-2012, 09:46 AM   #5
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Originally Posted by ddw350 View Post
i have been cutting and plating the frame,i got this jeep for under 2k and its in great to exc condition as far as cosmetics.. is rusty as all underneath.been workin on it an hour or 2 every eve so im gettin closer!
We are in the same boat. I have been working on my 2002 Wrangler, fixing and treating all the rust issues in the frame, and a few spots on the tub. A few hours every night, and the occasional weekend day. It's getting colder now in New England, and I only have the rear wheel wells left to do.

I am looking to do a small lift come springtime, so if you have any pictures of what your doing, and the final solution, they would be much appreciated. Good luck!

-Jim
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Old 12-10-2012, 06:39 PM   #6
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hey G-LOVE..sounds like we are in the same boat for sure! i also am doing a small lift and new shocks..mainly cause mine are so rusted! im sure bolts will break and everything else..but im in no hurry.i have it about 2 feet off the ground and am trying to get it the best i can. i actually had to make channel to go under and up the 2 sides due to the bottom was complety gone! i will try and snap a few pics but prob wont turn out to well..ill keep you posted..
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Old 12-10-2012, 08:52 PM   #7
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hey G-LOVE..sounds like we are in the same boat for sure! ... i actually had to make channel to go under and up the 2 sides due to the bottom was complety gone! i will try and snap a few pics but prob wont turn out to well..ill keep you posted..
We ARE in the same boat!!! I had two 26" x 3/16th inch steel channel made for the middle of my Jeep's frame. She's installed, and turned out amazing!!!

I too will throw up a picture, if you don't mind a thread hi-jack.

-Jim

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