Warbled out leaf spring hole

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Mildphil

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So back in 1999, my truck was fitted with aluminum side steps by the dealer (according to the original owner). The side steps mount to the frame at three points one of them being the leaf spring mount point. Since 1999, there has been NO nut holding the leaf spring bolt... uh oh. Because of this, I'm assuming the bolt has bounced up and down in the hole, warbling it out (pictures below). I want to fix this issue and put a nut there. I'm thinking of welding a washer in place to act as the new hole? Any better ideas?

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Hipster

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,I'm not sure you would find a washer that thick. If I was going to repair it I would be tempted to pick up a scrap or drop off the same thickness from whatever local steel supply you have and make my own washer along with a longer bolt. The hangars are not that hard to replace either. Grind the rivet heads off, pop the bracket off with an air chisel, knock/grind the rest of the pins out and bolt the new one on with grade 8 hardware with lock washers etc.

3M 3 inch weld grinding disks and/or a carbide burr on a die grinder make pretty short work of it.
 
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kennythewelder

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Replacing the bracket, is the best option. But the hole can be fill welded, and then drilled out to size. This would be a lot better than welding a washer to the bracket.
 

Mildphil

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Thanks for the ideas guys. I could try fill welding it like Kenny said, I do feel like that would be stronger than a washer too. I would like to avoid removing the bracket if at all possible. Drilling it out wider and sleeving it is also a good idea. I could find a tube with the proper ID to match the bolt, and then drill the hole out to match the tubes OD. I'd then weld it and grind the excess smooth. Gonna try and attempt it this weekend, I'll keep the thread updated.
 

Seaurchin1969

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Are you taking the step off, is the hole in the step wallowed out too? You could weld the step bracket to the hanger, if its not wallowed out, or if you remove the step cut that flange with the hole in it off the bracket, clamp it on and weld it, looks like there is enough stud sticking through to put a nut on it, or get a longer bolt.
 

Schurkey

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While there are better ways to do this...you might be able to get by with merely screwing a nut onto the bolt, and torquing it properly. As long as the spring is under load, it's not likely to move around. It's only when the load is released that it's going to move, and friction from the torqued nut is probably enough to stop that.

I'd be more concerned about wear to the side of the bolt (stress riser) than the wear on the hole in the bracket.
 

Supercharged111

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While there are better ways to do this...you might be able to get by with merely screwing a nut onto the bolt, and torquing it properly. As long as the spring is under load, it's not likely to move around. It's only when the load is released that it's going to move, and friction from the torqued nut is probably enough to stop that.

I'd be more concerned about wear to the side of the bolt (stress riser) than the wear on the hole in the bracket.

This is what I was thinking.
 

Chewy11B

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I'm confused why a simple welded washer wouldnt work??? Trailer manufacturers do it on trailers grossing over 20k.....would love to hear why.....
 
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