Top bolt on rear shock stripped. HELP!

The top bolt on the top of one of my rear shocks is to the point of being nearly stripped clean. I don't exactly know how this happened PO most have stripped it when installing a rear rack. I noticed in a few years back when I removed the rack. But was able to get the nut off and back on. Well I recently refinished the rack and was suddenly reminded that the bolt is nearly stripped clean of its threads. I was inspecting the bolt and I can't tell if it's casted/welded into the frame. Has anyone had any expereince with replacing this bolt? Is it welded/casted/pressed and more important is it fixable? I suppose I could tap the thread with a smaller bolt size but if anyone else has any better ideas/experience I'd like to hear it.

 

It's a welded-in stud (welded on the backside I believe.) You could saw it off, drill it out and replace it with a through-bolt; but if it were me, I'd re-thread it with a smaller size thread.

 

If you have some threads left farther on to the stud you might try one of these.

You slip it over the bad threads and close it around the good threads farther on and then spin it off the stud to save the threads.

They are kind of expensive but they have saved my butt a few times.

 

Rethreading OD threads would be tough, the studs not the right size and the old threads will complicate things.
It would be tricky but if you file the threads off and leave just the smooth shock mount, you could drill a hole in it, then tap the hole and use a bolt to hold the shock on.
How straight can you drill a hole?

 

Straight enough.. Hopefully.

What about chopping the whole thing off and then drilling out a hole on the left behind mount. Put a new bolt through maybe tack weld the bolt from the back side? Would the linear pressure be too much for the new bolt? I also worry about weaking the mount by doing your suggested method. More so I probably can't drill straight enough to make that plasuble, but will deff keep it in mind.

 

You could file the end of the shaft that sticks out past the shock and rack mount and re thread so you would not loose and lateral strength. Would not be easy but very doable. Re size the bolt to like an 1/8th inch inside the mount so you would get some compression on rack and shock.

 

Most of the bending strength comes from the outer 1/3 of the bar . As in a pipe is almost as hard to bend as a solid bar. If your going to drill it out, I'd drill that stud so its in the same place but stop before It's completely gone at a size you can get a grade 8 bolt in then tack weld the back . That needs to be strong and square.

 

Okay.. Best bet it to start with a tap, if that won't work I'll try polocks tip on drilling out the center and using a bolt from the outside. All else fails I'll chop it off and straight bolt through. Anyone know what size tap I need to rethread? At work now, can't check.

 

the stud on my 750 is 10 X1.25 , don't know about 550's