Originally Posted by evilfij
This is a pointless exercise. Get some square pieces of half inch steel, drill and tap, and cut off the old and weld on the new. Drilling 12.9 metric bolts is insane.
At that time, I did not want to mess with my X-member.... But after finding out later that it was rusting through (from the inside out, just like any other D90 X-member....), I would/should have done this! [Now.... welding upside down would still be interesting!
------ Follow up post added November 19th, 2013 04:59 PM ------
So many bonehead moves.... Are you really wanting to force us all to ridicule ourselves?
Went to home depot one winter evening, bought a few 8ft long (or whatever the standard size is) pieces of wood. Put them in my soft-top D90. They did not quite fit on top of the center console, so I place them on top of the dashboard. In the back, they did not quite fit inside the truck, so I opened the rear door and while holding them just above the rear door, I closed the door. Apparently, they also did not clear the tire....
Anyway.... got the windshield seal replaced at the same time as the glass. Not sure if that qualifies as "wrenching".
So a few wrenching ones:
- after I replaced the valley gasket on the 3.9L V8, the engine would not start. I figured I had screwed something badly (first "major" maintenance item I ever did on that truck)..... After counting how many pennies I had saved to buy a new engine, I came to my senses and looked for wires that were not connected. Found one going to the coil with a very loose connector on it. Plugged it back in and it fired right up.
- the disco made a clunking noise when making left turns. I figured the bushings needed to be replaced and did not think twice about it. Drove on it for a while, got a complete set of bushings from AB. Then at some point, I opened the passenger door and removed a bottle of water from the floor. Bushings are still in the bag, clunking noise is gone.
- recently did work on my rear axle (replaced wheel bearings). I had some noise left when the shock bushing was dying on me (well... dead really). I also had a vibration on the rear axle because I installed a rear diff protection plate and could never get it to fit snuggling to attach the top plate properly. Anyway, finally got to go back to the rear shock, undid my wheel and figured out that the mud shield was actually vibrating a lot due to the caliper bolts being barely threaded in..... Drove the truck 500+ miles with this....