Originally posted by markpat3
Could someone please offer some suggestions on the best way to re-mount the body back to the frame!!
I had to cut most of the bolts because the nuts were spinning up in the body. So I now need to somehow get new bolts in there, or something.
Has anyone had to do this before?
How did you tackle it?
Here is the way I do it and it requires a good amount of fabrication, experience and the right tools. When I restore a CJ, instead of just buying a complete steel tub, I buy all the individual body and floor panels and weld it all together myself. This way I'm insured of a perfect fit and no bad, unsafe welds. The front floor panel has the body mount positions done already with nuts inside the supports, but the rear floor panel does not.
Here is what I do:
I cut slots in the floor supports where they line up with the mounting points on the chassis about 1"x3". (That should allow you to remove the old spinning nuts in your case.)
Next, cut pieces of 1/8" thick steel 1"x4". Drill holes in the 1/8" plates a little bigger than the 3/8" bolts you'll be using. Fit a bolt through the hole, put a nut on the other side and tack weld the nut to the plate. One good tack on each side of the nut is a good idea, but make sure you allow it to cool between tacks otherwise the nut will warp. Remove the bolt and install the new assembly into the floor supports with the welded nut facing AWAY from where the bolt comes in. You're going to have to do a little hammering to get the new plate in there so be patient.
Once it's in there and the body is fitted up and bolted loosely to the chassis, mark where your new welded nut assemblies match up with the holes you cut in the floor support panel. Then tack weld the welded nut assembly to the floor support panel. All that's left is to prime and paint or POR 15 the area you worked on.
The toe supports (the two supports under the firewall) are done a little differently and are much easier. Once you remove the old welded nut assembly, you're pretty much done. Since you have access to those two nuts inside the toe support even when the body is mounted, you can just use a simple nut, bolt and a 2 washers.
Hopefully the 2 rear-most body mount bolts came out without you having to cut them, otherwise I really don't know what to tell you.
I know this all sounds complicated, but it's just about all you can do. I'd be interested if anyone else has any other ideas though.