Topic: Nerf bar bolts sheared off...

[GreenBayjeeper]

So I went a little nuts with my tax returns this year.  Not too bad, but among my Jeep goodies were some Rugged Ridge side steps.  So as to help my son get in.
Sort of a pain in the ass to install in the drive way, but my brother and I endured.
Fast forward a few weeks...
While driving I heard what I thought to be a rock hit the underside.  Then I heard it later in the week.  And then yesterday once more.
As I was crossing the parking lot, on approach to the Jeep, I saw a lighter patch on the nerf bar flange. Closer inspection revealed that two of the bolt heads on the driver's side front flange sheared (or popped or something) off.  One of them on the passenger side front flange too.

Now heres the question part;  WTF?!!!!!

The hardware was Grade 5.  That should be sufficient to hold on nerf bars, right?  They (Rugged Ridge) sent 12 self tapping Grade 5 bolts.  I'm gonna use Grade 8 hardened now, but it just pisses me off!
Fine thread bolts of the same size should thread into the holes now that the self tappers were in right?

[oldjeep]

The bolts actually broke off or were missing alltogether?   Hard to believe that a grade 5 could snap in that type of installation, I would expect it to just rip the threads out since there is not enough thread enguagement in the thickness of a frame for max strength.

[Jeffy]

My guess is that they were under tension from the other end of the nerf bar.  If there was any movement, they could have vibrated and fatigued the head enough to snap off.

[GreenBayjeeper]

Oldjeep, the bolt heads are gone.  It doesn't look like they sheared (upon further examination) but rather popped off.  Theres no apparent lateral movement, nor any high spots where the metal would have clung on (like an unclean cut).

And Jeffy, that could very well be, but I'm not sure how there would be tension on them.  I haven't driven more than 25 miles since I installed them a few weeks ago, and the front and rear flanges are on the same sections of frame rail.

I'm stumped.

I have a couple ideas on the fix though.  I may drill the holes big enough to weld some nuts into the frame and then use Grade 8's.  Or just use Grade 8's through the self tapped holes.  Not sure yet.

[Jeffy]

When you have one flange bolted down does the other sit flush against the frame still or does it pull away?  If it pulls away then that's part of the problem.  Retightening the bolts in different order might help.

If you want to get adventurous you might try getting some TJ nutserts from the dealer.  They are used to keep the stock steps on.

[aw12345]

you could try to find some nutserts, they are a pain to install but work fairly well those are the kinda nurs they use on the skid plate, the less welding on the frame the better sa,e goes for unnecesary drilling

[jcsanders79]

I have never had one come loose there should be hardly any tension on the nerf bar?  Sounds like a good excuse to upgrade to a rocker pannel that has a step bar on it!  Nerfs are ok looking but don't last long on the trail.

[Jeffy]

I have never had one come loose there should be hardly any tension on the nerf bar?  Sounds like a good excuse to upgrade to a rocker pannel that has a step bar on it!  Nerfs are ok looking but don't last long on the trail.

There shouldn't be any tension if properly installed.  I've had mine on since '93.  I've used them a jack points to lift the whole side of my Jeep as well.  Rocker panels are nice though.  You don't lose the ground clearance like you do with the nerfs.  Although even with a step, the panels are higher up.

[GreenBayjeeper]

Well, I replaced them with Grade 8's....  most of em.
Stupid me was thinking I needed 6, so I bought 8 in case I boogered up the threads - and I did on one.
Problem is that I need 6 per side.  So until the weekend, the ones that didn't shear are the ones that came with it.  It sits in the work parking lot 4 nights a week anyway, so I'm not too concerned.
And yes, the driver side one is under tension.  I didn't drill the holes perfect.  Now I gotta ream the holes on the flange.
Lesson learned?  Don't do things that require precision in the drive way.
Thanks for all the input though guys!