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Old 06-14-2013, 03:27 PM   #1
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Filing down for Ace Rock Rails

In the install video it seems pretty easy, the only part I'm not sure on is modifying the washer bolt. How can I file that down without a grinder? Can I just use a metal file? Is there something better?

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Old 06-14-2013, 03:37 PM   #2
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You need to remove enough material that you will be filing for quite awhile by hand. You can get a cheap grinder for under $40 or see if you can use one of somebody else's.

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Old 06-14-2013, 03:37 PM   #3
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Here's what I did today. Not really an expensive tool and if you do much to the jeep you will need one. Dewalts is about $90 and ryobi makes one for about $35.
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Old 06-14-2013, 03:42 PM   #4
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You would be much better off spending $20 on this than trying to do it with a file:

4" Angle Grinder
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Old 06-14-2013, 04:36 PM   #5
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I started with a metal file. Then I bought an attachment to my drill that was supposed to work as a cutting wheel. I also used a cheap dremel tool that I already had. Finally, I bought the grinder that X50ARM linked and cut them all in less than 10 minutes.
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Old 06-15-2013, 04:59 PM   #6
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I used a dremel tool with the cutting blade. Went through about 5 blades and took about 20 minutes.
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Old 06-15-2013, 05:41 PM   #7
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I love my ACE sliders. Had 'em for almost two years..... But,

Why doesn't ace provide washers that fit out of the box?

If they can fabricate those beautiful rails, certainly they can make, or find a supplier for, the right shaped washers!

Just askin'.....
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Old 06-15-2013, 05:43 PM   #8
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This might sound ignorent, BUT, why don't ACE just make the whole bigger instead of grinding..to me that just sounds ridicules.. Am I missing something ?
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Old 06-15-2013, 05:52 PM   #9
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Quote:
Originally Posted by jaxs1984 View Post
This might sound ignorent, BUT, why don't ACE just make the whole bigger instead of grinding..to me that just sounds ridicules.. Am I missing something ?
IIRC, ACE told me that rounding out the hole would reduce the strength of the mounting "box" beyond what they would be comfortable with.
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Old 06-15-2013, 06:01 PM   #10
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IIRC, ACE told me that rounding out the hole would reduce the strength of the mounting "box" beyond what they would be comfortable with.
OK that sounds reasonable I'm no engineer but , can't you just replace the OEM washer/bolt with a smaller one and then you don't have to grind away? .. [just thinking out-loud] ... I should look into that and start a business LOL
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Old 06-15-2013, 06:08 PM   #11
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Now that I think about it, the round washers are more or less permanently mounted on the body bolts, so replacing them would be harder than grinding them down.

Perhaps the mounting box should go back to the drawing board. The ACE guys are very good at what they do, I don't doubt they could come up with a better solution.

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