Valet
IS300 SX > Accord
While installing the bracket for my strut tower bar, I sheared one of the top hat's studs in half. I wasn't tightening it too much, but either way it happened.
So, instead of replacing the top hat, I have a simple solution.
Things you'll need:
-Flat head screw driver, a thick one, not something that will bend or break easily. The longer the better.
-Large metal mallet (4lb is plenty)
-Screw and nut. Thread doesn't matter, around 2 inches will be good.
-Grinding wheel
The first thing you're going to do, is punch the stud downward. You're going to put the flat head screw driver onto the stud, and smack the top of the handle with the mallet. Make sure your screw driver can handle it, and do not hit your fingers, hand, or wrist, theres a good chance of them breaking if you did. The stud will go down a little, but not much.
The next thing you're going to do, is take out your strut assembly. I am not going to write out how to do that or what is needed, that's another write up in itself. Once you have the assembly out, take off the top hat. There is a rubber/plastic backing under the hat, which is what is preventing you from punching the stud all the way through. Once you take out the backing thing, the sheared stud should fall out. It will look like this:
The thin end goes under the hat. It's about an eighth of an inch thick. So take your bolt, like this:
You will need to grind the head of the bolt down to 1/8", use a stationary grinding wheel. The kind that is motorized, bolted to your work bench, and has guards and stuff like that. Be sure to wear eye protection, and especially gloves. The bolt will get very very hot. So a cup of water to periodically dip the bolt in will also be a good thing to have, but not entirely necessary.
After grinding it down to size, put the new bolt through the hat like the sheared one you replaced. It doesn't need any kind of adhesive. Put the backing thing back in, and screw the hat back down onto the strut. Put the strut assembly back in, and screw it all down. And there ya go:
If you have any questions, feel free to ask.
-Shawn
So, instead of replacing the top hat, I have a simple solution.
Things you'll need:
-Flat head screw driver, a thick one, not something that will bend or break easily. The longer the better.
-Large metal mallet (4lb is plenty)
-Screw and nut. Thread doesn't matter, around 2 inches will be good.
-Grinding wheel
The first thing you're going to do, is punch the stud downward. You're going to put the flat head screw driver onto the stud, and smack the top of the handle with the mallet. Make sure your screw driver can handle it, and do not hit your fingers, hand, or wrist, theres a good chance of them breaking if you did. The stud will go down a little, but not much.
The next thing you're going to do, is take out your strut assembly. I am not going to write out how to do that or what is needed, that's another write up in itself. Once you have the assembly out, take off the top hat. There is a rubber/plastic backing under the hat, which is what is preventing you from punching the stud all the way through. Once you take out the backing thing, the sheared stud should fall out. It will look like this:
The thin end goes under the hat. It's about an eighth of an inch thick. So take your bolt, like this:
You will need to grind the head of the bolt down to 1/8", use a stationary grinding wheel. The kind that is motorized, bolted to your work bench, and has guards and stuff like that. Be sure to wear eye protection, and especially gloves. The bolt will get very very hot. So a cup of water to periodically dip the bolt in will also be a good thing to have, but not entirely necessary.
After grinding it down to size, put the new bolt through the hat like the sheared one you replaced. It doesn't need any kind of adhesive. Put the backing thing back in, and screw the hat back down onto the strut. Put the strut assembly back in, and screw it all down. And there ya go:
If you have any questions, feel free to ask.
-Shawn
