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Old 12-24-2009, 06:38 PM   #496 (permalink)
Christ
Moderate your Moderation.
 
Join Date: Nov 2008
Location: Troy, Pa.
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Pasta - '96 Volkswagen Passat TDi
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Ben -
If you drill through anywhere on the car, you won't be able to tap it. The threads that you see are actually nuts welded to the other side of those holes. The only way you're going to be able to do something like that is to weld a plate to the spot that you want to drill, then thread the plate and bolt it in, or use the cross member, like we discussed last week. The cross member is 1/8" plate, and you can drill clean through both sides of it and use a nut/bolt all the way through. This will also allow you to use the entire length of the clutch cable, while minimizing the length of hydraulic line that needs to be used.

If you still wanted to go ahead with where you were already mounting, you can either weld a plate there and mount it, or you can put a nut on the end of a bolt, hold the nut in place using pliers on the bolt, and weld it to the sheet metal.

Also, if you don't plan on using the tow hook on that side, why not just use the existing holes? Unless you have a modified front cross member or you actually plan on having the tow-hook installed, there's no good reason it couldn't be mounted there.
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