Using bolts and nuts on torque box panel

[Whitetrash]

May be a dumb question, but it is time for me to replace the torque boxes on my project TJ, since the body mounts in the center have rusted through completely. I understand how to replace the entire piece, drilling out the pinch/spot welds, and that it should be pinch welded back on with some body panel adhesive. I saw one thread where someone used rivets and said it held up ok...has anyone used bolts and washers in the old drilled out pinch weld holes? I would think it would be just as strong as a small pinch weld, since there is so many of them. May be a dumb idea, but knowing that I lack a welder (but have dang near everything else) I was curious what everyone else thought or if anyone else has done it that way.
Side note-I know that welding is the preferred method, period. Just seeing if someone has ever done an alternative. this is a budget $400 TJ that I bought from my boss with a 2.5 with a broken piston skirt, so trying to do small things to bring it back to life on a budget.

 

[Imapepper]

For the cost of the nuts, bolts and washers you could probably afford a cheapo welder. Check out safetcaps and similar, cut out rust, cover with cap, stitch weld...... or nuts n bolts...

 

[-T.]

I can't see why it wouldn't work just fine, honestly.

 

[Whitetrash]

For the cost of the nuts, bolts and washers you could probably afford a cheapo welder. Check out safetcaps and similar, cut out rust, cover with cap, stitch weld...... or nuts n bolts...

Luckily for me at my job I have access to all the hardware I could ever need supplied by Fastenal...so it’s free. I do get what you’re saying though. I have seen the Safetcaps replacement parts, just would need it welded.

 

[Drizit]

It would work, but it's such a critical area with so much flexing you would probably need to retorque the bolts about once a week as they back off

—
There must have been a time
when we could have said no.

 

[astjp2]

You would need to install about 800 bolts to spread the load properly...and keep things from tearing out.

 

[Whitetrash]

You would need to install about 800 bolts to spread the load properly...and keep things from tearing out.

I hear what you’re saying. I guess what doesn’t make a ton of sense and confuses me is that - what causes the pinch welds from the factory not to just tear or break after a few years? But thanks for the feedback!!

 

[astjp2]

there is a lot of them

 

[davidgoodman]

I just replaced mine, and the floorboards. It is a rather big job.
The bolts would hold it in place. The issue is that while this is a body on frame vehicle, the body has several units incorporated in it that make it more or less a unibody construction in itself.
What condition are your floorboards in? They need to be in good shape as they hold the bulk of the welds.
If the floorboards were in very good condition then the bolts would probably do OK with the addition of panel adhesive. The spot welds are about every 3 inches BTW.

 

[Whitetrash]

I just replaced mine, and the floorboards. It is a rather big job.
The bolts would hold it in place. The issue is that while this is a body on frame vehicle, the body has several units incorporated in it that make it more or less a unibody construction in itself.
What condition are your floorboards in? They need to be in good shape as they hold the bulk of the welds.
If the floorboards were in very good condition then the bolts would probably do OK with the addition of panel adhesive. The spot welds are about every 3 inches BTW.

The floorboards are currently being replaced by myself, I cut out the old rusty parts earlier and going to rivet in the new pans tomorrow. So in turn the floor pans will basically be new

 

[Vtx531]

Any updates?

I just bought a nice welder to do floorpans, torque boxes, rockers, rear crossbrace, frame repair.

I plan on selling the welder when I’m done because I much prefer bolted connections whenever possible and I can’t see myself using it for anything else.

It seems like bolts would be stronger than spot welds. Assuming Jeep used spot welds for manufacturing speed and cost. How great would it be in 10-20 years if they rust out again to simply bolt on some new torque boxes?

I have a bolt together together HF trailer that is solid as a rock. I can’t figure out why anyone would “upgrade” it by welding it together unless you are doing something wrong.

So ya, I got this welder and capabilities now but I don’t want to use it unless neccesary.