So, I have the end of the shackle bolt sheared off into the welded nut attached to the unibody. I welded a nut to the broken bolt to try and turn it out, but it wouldn't budge. Heat and PB blaster did nothing, so I turned to the 3lb hammer and punch set to try and get it to turn with force. Well, the whole bracket gave way and has torn open about the welded nut. I am new to welding and don't want to resort to fabricating new shackle brackets if I can help it.

What are my options here?

 

I hind sight, drilling it out would have been good.

I see three options

1. If you can drill it out the broken bolt, restore the threads, then bend back into shape and weld the tear.
2. remove the whole bracket and replace with like, new? or used from a wreck.
3. Cut out the existing nut and its surrounding metal enough to weld in lap joint style a disc of sheet metal with a new nut prewelded to it this will neessecitate you having to shorten the bushing center by the added sheet metal thickness, and easy job with a grinder

Good Luck!

 

That was my original thought, but I couldn't hit the bolt straight with the drill because my quarter panel was in the way. Also the 10.9 bolt was putting up a fight with my drill bits! I've done some scoping around and there are aftermarket brackets that replace the sheet metal brackets and just bolt in. Still going to a big box store first to see if I throw something together cheaper with some square tubing.

Thanks for your response!

I'll update when I get it done so the next poor fool the end up like me can have an idea of what to do lol.

 

In a pinch I have gotten the correct drill and cut it short enough and used it together with my right angle chuck. Not fun, but sometimes it works.

 

What I would do is get a nut the size you need for the bolt and weld the nut to a thick washer cut out the old one that's haft way out fit the hole to the washer and weld it in the grind it smooth and there it is fixed . I know it's more work then it sounds .