Sylvie Willis
Installing and repairing bolts on a fuel tank strap can be a challenging task, as demonstrated by several online accounts of people's experiences. The process often involves removing the fuel tank and dealing with rusted or broken bolts. Some common approaches include using an impact wrench or air hammer to remove the bolts, cutting off the bolt heads, drilling out the bolts, and using a thread tap to create new threads for the replacement bolts. The Dorman 55157 Fuel Tank Strap Hardware Kit is a popular option for replacement bolts, although some customers have reported issues with bolt length and metal quality.
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What You'll Learn
Removing a broken bolt
Firstly, it is recommended to try simpler methods before moving on to more complex solutions. Soaking the bolt with a lubricant for some time might help loosen it. Vice grips or locking pliers can also be used to try and remove the bolt. If the bolt is stuck and there is enough of it sticking out, you could try cutting a slot in it and then using a flat-head screwdriver to remove it.
If the above methods do not work, you may need to try drilling it out. Before drilling, use duct tape to seal the hole and catch the metal filings. Drill a small pilot hole as straight as possible, and then drill a larger hole of the necessary size for the new bolt. It is important to drill straight to ensure the new bolt fits easily.
If the bolt is still stuck, you might need to get creative. Some people have suggested using an air hammer and chisel to cut the bolt head off, or even welding a nut onto the bolt and taking it from there. However, these methods may be more dangerous and require more expertise.
In any case, it is important to take your time and not cause further damage. If you feel out of your depth, it is always best to consult a professional or someone with more experience.
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Drilling a new hole
Preparation
Before drilling, it is essential to have the necessary tools and take safety precautions. Ensure you have a quality metal drill bit, a thread tap, and a metal punch. It is also important to work with caution, as drilling near a fuel tank can be hazardous. Make sure the area is well-ventilated, and consider draining the fuel tank before starting.
Flattening the Broken Bolt
Use a hacksaw blade or a Dremel saw to flatten the broken bolt as much as possible. Creating a flat, level surface on the broken bolt is crucial for drilling a straight hole. Take your time with this step, as a flat surface will ensure a more precise drilling process.
Drilling a Pilot Hole
Use a smaller metal drill bit to drill a pilot hole first. This initial hole will guide the drilling of the larger hole and make the process easier. Ensure the pilot hole is drilled as straight as possible, maintaining a vertical alignment. Use the metal punch to create a dent on the bolt, which will prevent the drill bit from wandering.
Drilling the Larger Hole
After the pilot hole is drilled, proceed to drill a larger hole of the necessary size for the new bolt. Again, maintain a straight and vertical drilling alignment. Be cautious and patient during this step, as drilling at an angle can result in the new bolt not fitting properly.
Cleaning and Threading
Once the larger hole is drilled, clean up the metal shavings as frequently as possible to minimise debris falling into the fuel tank. Then, use a vise grip pliers to hold the round collar of the bolt while turning the thread tap to cut new threads. Turn the tap a couple of turns, back it out, clean it, and then continue further. Do not force the thread tap, and stop if it becomes hard to turn to avoid breaking the cutting teeth.
Safety Precautions
Some sources recommend taking extra safety measures, such as sealing the hole with duct tape and placing wadded duct tape inside the tank to catch metal filings during drilling. Additionally, always wear appropriate safety gear, including eye protection and gloves, when performing these tasks.
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Choosing replacement bolts
When choosing replacement bolts for your fuel tank strap, there are several factors to consider to ensure a successful repair.
Firstly, it is important to select bolts of the appropriate length. In some cases, bolts that are slightly longer than the original ones may aid in strap installation and provide a better grip. This is especially true if there is ample room behind the U-nuts, barrel nuts, or body nuts to accommodate the longer bolts. However, it is crucial to ensure that the bolts are not too long, as this can cause issues with the strap fitting properly.
Secondly, the diameter of the bolts should match the size of the holes in the fuel tank strap. If the holes in the strap are larger than the original bolts, you may need to drill larger holes to accommodate the new bolts. It is important to drill these holes as straight as possible to ensure a proper fit.
Thirdly, the thread type and pitch of the bolts should match the original bolts. The thread type refers to the shape and angle of the threads, and it is important to get this right to ensure the bolts screw in properly. The pitch refers to the distance between the threads, and matching the pitch will ensure the bolts fit securely.
Additionally, it is important to consider the quality of the bolts. Some fuel tank strap hardware kits have been described as feeling cheap and appearing to be made of pot metal. It is advisable to opt for bolts made of high-quality materials that are durable and rust-resistant, especially if you live in an area with harsh weather conditions.
Finally, it is worth noting that some fuel tank straps may require specific types of bolts or hardware. For example, certain straps may use U-nuts, barrel nuts, or body nuts, so it is important to identify the specific requirements of your fuel tank strap before selecting replacement bolts.
By considering these factors, you can make an informed decision when choosing replacement bolts for your fuel tank strap repair.
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Using a thread tap
To repair the fuel tank strap bolts of your Foreman, you will need to remove the sending unit from the fuel tank. Start by soaking the bolts with penetrating liquid for a few days to help loosen them. If the bolts are stubborn, you may need to break them and repair them afterward.
Once the bolts are removed, you can begin the process of installing the repair bolts using a thread tap. Here is a step-by-step guide:
- Drill a small pilot hole as straight as possible. This will guide your larger hole and ensure it is straight. Use a smaller metal drill bit to make this process easier and use a metal punch to create a dent on the bolt to prevent the drill bit from wandering.
- Drill a larger hole of the necessary size for the new bolt. Ensure you drill this straight as well, as any angle can cause the new bolt to not fit through the sending unit's hole.
- Clean up the metal shavings as frequently as possible to minimize debris falling into the tank.
- It is now time to tap new threads. If the round collars are spinning, use vise grip pliers to hold them as you turn the thread tap.
- Turn the thread tap a couple of turns, then back it out and clean it off. Repeat this process, advancing a little further each time. Do not force it; you should be able to feel it cutting the metal easily. If it becomes hard to turn, stop and back it out to avoid breaking the cutting teeth.
- Continue the above process until the tap is all the way through and the new threads are finished.
This process will help you repair the fuel tank strap bolts on your Foreman, ensuring a secure and safe installation. Remember to take your time, work carefully, and always prioritize your safety when working with fuel tanks and power tools.
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Longer bolts for easier installation
The use of longer bolts can make the installation process easier during fuel tank strap repairs. This is because a longer bolt provides more torque, enabling the application of force over a larger distance. In other words, the longer the wrench, the bigger the difference between how far the wrench moves and how far the bolt moves. This is due to leverage, which can be understood by imagining a see-saw. When you sit on a see-saw, if you're sitting closer to the middle, you need to push harder with your legs to lift yourself up. However, if you sit further away from the middle, it becomes easier to lift yourself up as the longer distance multiplies the force.
When repairing fuel tank straps, it is important to note that the bolts may be stuck or challenging to remove. In such cases, it is recommended to use an impact tool or an air hammer and chisel to remove the bolt. Additionally, it is crucial to be cautious and prioritize safety when working with fuel tanks to prevent accidents or injuries.
To install a new bolt during fuel tank strap repair, it is essential to ensure that the hole is drilled straight and clean. This can be achieved by using a small pilot hole as a guide and drilling as straight as possible. The use of a hacksaw blade or a similar tool can help flatten the broken bolt and create a level surface for drilling. Once the new hole is drilled, it is crucial to clean up any metal shavings to minimize debris in the tank.
When selecting a replacement bolt, it is recommended to choose one with a smaller thread size than the original bolt to utilize the round collar at the base effectively. This can provide a better fit and minimize the number of threads cutting into the parent material. Additionally, the use of duct tape can help seal the hole and catch metal filings during the drilling process.
Overall, using longer bolts during fuel tank strap repair can make the installation process easier by providing more torque and leverage. However, it is important to follow safety precautions and carefully drill and clean the holes to ensure a successful repair.
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Frequently asked questions
Removing the bolt that holds the fuel tank strap can be a challenging task. Here are some suggested methods:
- Soak the bolt with penetrating liquid for several days to loosen it.
- Use an air hammer and chisel to cut off the bolt head.
- Drill a small pilot hole straight up and down, then drill a larger hole for the new bolt.
- Use an impact wrench to apply force and try to pull the strap down so that the bolt comes out with it.
When repairing broken bolts on a fuel tank, it is important to take your time and work carefully. Here are some suggested steps:
- Drain the fuel tank and seal the hole with duct tape.
- Use a hacksaw blade or a Dremel saw to flatten the broken bolt and create a flat, level surface.
- Drill a straight hole through the broken bolt, using a metal drill bit and a thread tap.
- Clean up metal shavings frequently to minimize debris falling into the tank.
- Tap new threads into the hole, being careful not to force it and turning it a couple of times before backing it out.
There are several products available for replacing fuel tank strap bolts. Here are some options:
- Dorman 55157 Fuel Tank Strap Hardware Kit: Compatible with select models, including Chevy Silverado 1500, 1992 Blazer, and 2007 Tahoe.
- Amazon offers a variety of fuel tank strap bolts, including longer bolts that aid in strap installation.
- Summit Racing offers fuel tank mounting strap fasteners and hardware for various vehicle models, including Buick, Chevy, GMC, and Ford Mustang.
Here are some tips for installing and maintaining fuel tank straps:
- Before installation, apply a couple of extra coats of paint to the straps, especially if you live in an area with high humidity or salt exposure.
- When removing bolts, be cautious of any sparks that could potentially cause an explosion.
- Consider using longer bolts than the originals for easier installation and added security.
- If you are dropping the entire tank, consider replacing the sender unit as well, as they have a limited lifespan.
