broken headlight support blind nut - options?
Thread Starter
Intermediate
Joined: Sep 2001
Posts: 26
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From: Burnaby BC
broken headlight support blind nut - options?
Removed my headlight assemblies and got a couple of surprises on the the passenger side unit. A front tab on the support was missing and wedged in place using a steel tab!? Easy but expensive fix to buy a new support frame. The next issue is a little more problematic. The back of the headlight support frame bolts to a steel support bonded into the nose. The outside bolt on the passenger side is spinning freely. I assume that the nut welded inside has broken loose. Fortunately this location uses a slot in the headlight support, so I got the frame out and have open (relatively) access to the bolt. What are my repair options short of removing this bonded support? It feels like the bond frame is open ended so can i cut the bolt and fish the offending nut out? What is my best approach to replacing the nut? Thanks in advance for any suggestions.
Last edited by msn71; Jan 1, 2010 at 08:07 PM.
Race Director
Joined: Sep 2004
Posts: 11,874
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From: Arlington Va Current ride 04 vert, previous vettes: 69 vert, 77 resto mod
for the repair of the front ,i have a driver vette so i really wasnt worried so much about it being a perfect restoration only a good solid repair so i welded a tab on the frame and then bolted and epoxyed it to the headlight support. let me get some pictures.
Last edited by bobs77vet; Jan 1, 2010 at 07:54 PM.
Former Vendor
Joined: Aug 2006
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From: Jeffersonville Indiana 812-288-7103
St. Jude Donor '08-'09-'10-'11-'12-'13-'14-'15
MSN71-
The header bar is open on the end and yes your worst nightmare is going to be getting in there. The nut was welded to the original header and if the nut is turning you'll have to find a way to get it attached back.
You could cut the old bolt off and then cut a slot next to the hole and use a J nut in there, or you could attempt to feed the nut in place from the open end. I don't know if this is possible.. (I have larger hands).
Either method would not be to bad to fix...
Without replacing the header bar you could also cut out a square section from the header and weld in a new one with the nut attached. This is a harder option but something that could be done. And one last choice would be one of the newer body panel expander nuts. I've seen someone post these on here before and are like a large wall anchor nut.
If you need the supports, we have them in the forum special price section of the site too. http://willcoxcorvette.com/advanced_...ywords=support
Happy Holidays
Willcox Inc.
The header bar is open on the end and yes your worst nightmare is going to be getting in there. The nut was welded to the original header and if the nut is turning you'll have to find a way to get it attached back.
You could cut the old bolt off and then cut a slot next to the hole and use a J nut in there, or you could attempt to feed the nut in place from the open end. I don't know if this is possible.. (I have larger hands).
Either method would not be to bad to fix...
Without replacing the header bar you could also cut out a square section from the header and weld in a new one with the nut attached. This is a harder option but something that could be done. And one last choice would be one of the newer body panel expander nuts. I've seen someone post these on here before and are like a large wall anchor nut.
If you need the supports, we have them in the forum special price section of the site too. http://willcoxcorvette.com/advanced_...ywords=support
Happy Holidays
Willcox Inc.
Thread Starter
Intermediate
Joined: Sep 2001
Posts: 26
Likes: 0
From: Burnaby BC
Thanks for the suggestions. The car is not an NCRS queen, I just want the least Bubba solution! I will definitely cut out the old bolt and nut. Once I can assess the access better, I will either cut out a section, weld on a nut and weld the section back in or open up the existing hole to take a suitable nut and weld that in flush. Thanks for the link on the support frame! regards, Stephen
