Having a great, but also rubbish (substitute cr*p) day

Birthday today - got a great present a rear NAS bumper - so thought, would quickly fit it this morning and its a nightmare, dont know why but it is/has been and im at a loss on what to do.

Some minor bolt problems throughout - but the current major one the inserts that go in the jacking points - one of the bolts, one bolt from the kit didnt want to go in, the other did by hand and got reall tight, took out, checked (all ok) applied grease, it went a bit further, tight again, did above got within 5mm of being all the way home, it got really tight (also heard a slight crack noise) withdrew it. The threads on the bolt (extreme end) had flatterned.

So got a new bolt - went in much better but has got tight about 50% in and now im worried about pushing through it with a socket in case the crack i heard was some welded nut going.

There are some other bolt problems with the stays attaching to the tank (so far they are not fitted) i had issues with the outside bolts, ending up reusing the torx ones fitted as standard as the provided ones again were not long enough. Thats before i mention some finish problems i had to repair

So really i need some thoughts/help on the current jacking point bolt problem - what should i do, it has not made my birthday the best ever, despite me loving it, so your input/suggestions would really help, obviously i dont want to shear anything not knowing how these threaded points fix.

Help
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Mike
2.4TDCi 90CWS XS
300TDi Discovery

jeezus mate that sounds tragic !
Just ordered one myself now wondering if I should not bother ?
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DEFENDER XS CSW 08 TONGA GREEN

It is and ive no idea what to do with this bolt.

So far the issues were:
Coating damage (ive fixed that)
The stay bar between bumper and bottom of crossmemeber - issues fitting due to CSW rear step (got that in eventually)
Bolt issues with the bolts each side for the seat
Bolts no fitting the extension stays into the ready made bolt holds (not yet sure how to progress this)
and finally this bolt which is my biggest headache.

Im wondering if i should send it back, but with the repairs ive done to fit it, they probably wouldnt have it back.

If i can get this bolt issue sorted (my big worry if you havent guessed) im sure i can overcome the rest. It looks good. (i need to talk to you so ill send a pm!)
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Mike
2.4TDCi 90CWS XS
300TDi Discovery

If the holes are threaded there may be some rust or paint that needs to be removed. Tap them out with a suitable size tap first.

If they go through the jacking holes these may have been distorted due to jacking the vehicle up at some stage. Personally I would get a drill about 0.1 or 0.2mm larger tahn the bolt and run it through first. Repaint the tube or apply grease where the metal/paint is removed. If the bolt passes through the hole without the step on it then I would be looking at opening out the holes in the step slightly. Don't give up. Sometimes these things take a bit of fine tuning. I'm sure it will be worth it in the end.
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Land Rovers are an addiction. Toyotas are for quitters.

WWW.CQLROC.ORG

Thats reassuring - thanks.

I didnt think of re tapping the hole.

hopefully ive not damaged anything holding it in place - i think it looks like removing it at the weekend and exploring it in more detail, with a view to retapping the hole.
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Mike
2.4TDCi 90CWS XS
300TDi Discovery

Well i removed it had one look and contacted the dealers - they were as good as gold and its going back and a new one is in the post.

hopefully second time is a charm.
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Mike
2.4TDCi 90CWS XS
300TDi Discovery

Happy Birthday anyway Mike.
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2.4 90 XS
1968 1/32 scale Britains 109 Pick up.

THank you - hopefully alls well that ends well.
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Mike
2.4TDCi 90CWS XS
300TDi Discovery

MSE,
I had similar problems when I fitted a NAS bumper to my 83. The jack holes typically have years of rust build up and I ended up using an 8lb hammer and a block of wood to encourage the bumper into place. Once on the truck I had the same issue as you only I was using an impact gun and twisted the bolt right off so had to drill it out and retap. As a precation I retapped the other side as well and everything went smoothly.
Cheers,
Doug

This was brand new, but its been replaced and the new one is on and fits perfectly.

The old one was faulty, its a shame the finish on the new one was almost perfect.
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Mike
2.4TDCi 90CWS XS
300TDi Discovery