by Chuck Phlegm
Just another thing to do to your Bronco!
Every time you take the hardtop off your Bronco, you are faced with the dreary task of putting the bolts and nuts somewhere safe. Not only that, but your Bronco has that line of 7 holes on each bed rail, looking a little unfinished.
About a year ago, talk on the Broncofix list turned to a handy piece of hardware called a "nutsert." Using a tool similar to a rivet gun, you could put a blind threaded insert into these holes and have one less thing to lose when you peel the top off the old steed.
I bought the tool. It was $12.99 at Harbor Freight. It came with several heads and a handful of each size "nutsert." I was pretty sure that 14 1/4-20 bolts (plus the 5 or 6 across the windshield header) would hold the top on, but when I realized the inserts were some sort of soft ferrous metal, I was a little less impressed. So the tool sits out in the garage. It looks damn good hanging there. I turned to other things that Alice needed more than nuts... like, say... brakes.
A few weeks ago I was in my local Ace Hardware store looking for nothing much. I happened across a bin with threaded inserts. They are manufactured by a company called Midwest Fastener Corp (http://www.fastenerconnection.com/aboutus.asp). Upon inspection, they are made of heavier material than the nutserts I tried previously. Also, they don't require an expensive tool to install. There is a "tool" to buy that will do the job (I'm a tool junkie, so I bought it). It is basically an oversized nut with a smooth bore (no threads). The idea is to put this nut on a 1-1/2" bolt that fits the insert, then thread the insert on, then put the whole assembly in the hole. Using 2 open end wrenches, or a wrench & ratchet, you tighten the bolt and compress the insert.
The inserts cost me about $1.30 each, and the tool was about $2. It was a quick job. Figure about an hour. See the photos below for all the gory details.
The 5/16" inserts I used needed a 9/16" hole. To make the job easier, you can clamp a scrap of wood under the bedrail where you will be drilling. I was a man and just toughed it out when the drill attempted to remove my wrists.
The three magic pieces. You could substitute the nifty tool for an oversized nut. I decided to pony up the $1.90.
Put them all together. Nut or tool first, then the insert threads right on.
Stick it all in the hole.
I used an open end wrench and a deep socket. It was a little easier when I switched to a ratcheting box-end wrench. Both work. Keep the insert snug in the hole so it doesn't turn out crooked as it compresses.
Too cool? I think so!
-Chuck Phlegm
I can get enough to do my bedrails AND my windshield for less than what it would take buy enough for the bedrails at a local hardware store. I had to go to 4 different hardware stores before I found them too! So check it out at 
