Relocate sway bar disconnect retaining pin, need tap & die set

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Kingston Peak yesterday was the second trail run since I installed my 33" tires. On the downhill switchbacks at the end of the run, I had some rubbing when turning to the right. I didn't think much of it, besides to let off on how far I turned right, until I finished the run and went to reconnect my sway bar. Apparently the rubbing was the tire on the sway bar disconnect retaining pin. The locking ring on my linch pin was gone, apparently dislodged by the tire when it rubbed. For the my JKS quick disconnect kit, I have retaining pins (posts) to bolt into the frame. The intent is to move the sway bar onto the retaining pin while off-roading, and thereby keep the sway bar (and retaining pin) from contacting any other components. The tire should *definitely* not hit this, since it could cause a tire failure. This pin/post was installed by the previous owner, and was installed too low on the frame, on the driver side of the Jeep. The passenger side pin/post is installed much higher on the frame, and appears to not be an issue.

Going by the installation instructions for the kit, at https://www.quadratec.com/sites/defa...ions/11405.pdf, it appears I need to drill a new hole and tap it with a 5/16" x 18 TPI tap. I do not have a tap and die set, nor have I ever used one. I also do not think I have an appropriately sized drill bit (Size "F", per instructions). If anyone is nearby and has appropriate tools, I'd appreciate some assistance or the opportunity to borrow what I need to fix this sometime. How much effort is it to drill a ~0.25" hole through one side of the frame box? It looks like a pretty easy job, though I don't want to screw it up and put many more extra holes into my frame.

Follow on question -- should I just paint the old tapped hole and leave it as is? Is this something I should instead get someone to weld in/over to fill the old hole in?

[Hypoid]

I have taps & dies, and experience. I'm not sure if I have an "F" drill, but my local hardware does.

I'd paint the old hole and call it good, no reason to put heat to the frame.

[Mobyjeep]

Home Depot sells a tapping drill bit that is for steel I’ve used them several times work great. If you have a battery impact driver. I’m pretty sure they come in 5/16” and they cost around $10

[Mobyjeep]

Here it is and it’s an f drill bit

[Brian]

Mobyjeep previously posted:

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Looks like a coworker is loaning me a tap and die. Maybe tomorrow night I'll be able to finish this out. Will hit up home depot for at least the F bit, but probably a good idea to pick up that combo set with corresponding tap, and use the loaner tap set for the handle.

[RockyMtRebel]

There should be an existing hole where you should install the pin, I know on both my’04 & ‘05 there are. I bought a pair of these pins and they screwed right in without needing to tap. On the ‘04 I accidentally forgot to disconnect one side and it broke the pin off on the other.... so now it needs to be tapped..... I’ve hand tapped these before with no issues. I’d snap a couple pics but I’m not at home currently.

[RockyMtRebel]

Also, you may want to consider installing some wheel spacers to avoid tire rub. I installed Spidertrax 1.25” spacers on my fronts because the 35” tires were rubbing and now I’m fine

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RockyMtRebel previously posted:

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I knocked this out last night with a loaned tap. Easy and quick with the right tool.