That's it, I'm DONE! '62 cj5 mechanical to electric fuel pump conversion

Ok, that's it. I'm done. I took on the project of overhauling the entire fuel system on my new to me '62 Jeep CJ5. When I pulled everything out, it was AMAZING how screwed up everything was with corrosion and well, some kind of disgusting gunk.

I got a new tank, all new fuel line, new fuel pump, and carb. Then I screwed up. While installing the new fuel pump, I messed up and sheared off the bolt on the front side. Between the engine, frame and the all the tight corners I can't even get to the bolt to get it out. I've tried everything I can to get to the dang thing to get it out, and I can't get the dang thing to move at all. Vise grips, tiny pipe wrench, bolt extractors, you name it.

With the clearance as tight as it is, there is no way that I'm getting an interior extractor in even if I pull the front corner panel, so to get it out the only way I'm thinking that I'm getting the stupid thing out of it is to pull the engine (which I'm not doing to install a fuel pump).

So, I'm going electric and that brings me to my question. What is the best way to plug up the hole on the side of the engine that is not permanent? I ask because down the road when I do pull the engine and overhaul it (which I don't have the cash for right now) I figure at that I'll finish extracting the bolt and reinstall the mechanical.

Is there an aftermarket plug that will cover up the hole left without the mechanical fuel pump bolted up there? Anyone have a good solution to this?...

Thanks in advance!

 

I think you'll need both bolt holes clear/open to bolt down the cover.

Not that you have the room, but you will likely need to drill out the bolt shaft to get it out. You might get lucky and find that drilling out just the center of the bolt releases enough of the lateral and compression tension to get a bolt extractor to do its job.

 

Whelp, looks like I see a new right angle drill in my future! Look on the bright side, the money I would have spent on the electric pump conversion will now get me a new toy!

 

Pulling the fender and wheel off would make getting to the area easier. JM2C Tom

 

I was going to say the same thing. The fenders and grille come off fairly easily.

Dealing with a stuck bolt can be rough but it builds character!

Good luck

 

Drill it out with left handed drills. I have had great luck using them.

 

Once the bolt is out, there are block off plates made for fuel pumps. You may find one that fits as most mechanical fuel are fairly similar is their shapes where they mount. May have alter is shape a bit for a perfect fit. Or, you could make your own with a piece of steel or aluminum plate.

 

If there is still a nub of bolt left try heating it to hot and apply canning wax till the melting slows down a little let it cool for a few and try to remove it again. Done this to many broken exhaust studs I have about a 90 percent success rate.

 

Mine came with an electric pump. I couldn't wait to pull that out. When I went to remove the plate it was glued on. The PO had also broken the bolt off for the pump and just glued a plate over it. My little cordless drill worked just fine for drilling out.