1. Was the purpose of drilling holes for bolting on your side box?
2. Didn't the main lower box already have thread inserts for bolting on the side box?
3. How are you able to tighten the nuts on the other side of the inner wall of the main lower box?
I'm confused as hell.
1. The purpose of drilling holes for the side box was to bolt it on and permanently attach it. Before it just "hung" on a lip on the bottom box so it wasn't safe/secure and it would move, i didn't want that, i wanted it bolted solid together.
2. There are captive nuts in the bottom frame of the top box. They take small bolts (~1/4" thread, 3/8" head.) but i wanted bigger ones, so i drilled the threads out and used metric M8 bolts with a 13mm head and nyolc nuts. I'll add another 4 bolts sometime later on. This stops the top box moving and stops anyone from being able to steal it.
3. When i drilled the (8) holes to attach the side box to the bottom box i measured where the slots are for the slides and lined them up, that way i could use the slots to insert the nuts/bolts/washers into the holes i drilled and i then i used a 1/4" socket and extension to tighten them. You can't really see it in this pic, but the holes are staggered to meet with the slots on the inside:
The side handle was much harder to do, i measured the hole pattern from the bottom box and transferred it over to the side box. The front bolt holes almost met with the slots for the slides, a distributor wrench held one of the forward nuts while a crowfoot was used for the other. The rears were much harder, as they weren't near the slots. I used a magnet to place the washers on the bolts (i laid the box on its side, passed them through the forward slots and flicked them over to the magnet which was fed through a rear slot) the nuts were placed in a similar way (masking tape held them on the magnet, i turned the bolts from the outside to get the threads started, i then slipped a 10x13mm wrench through one of the front slots, got it in place with the magnet and used a 1/4" driver to hold it steady while i tightened the bolts from the outside with a ratchet.
Does that help explain?
-Moose.
i should have done your way, too.
You still can. It's frustrating but well worth it.
