Suggestions on a sheared bolt in frame nightmare

So I'm military and was installing my new Icon setup on my 2014 and when trying to get the stock bolts into the frame where the sway bar bolts in, they weren't going in, like the threads were messed up. So being military I was doing the work at the post auto shop which has mechanics there to help out so I asked one and he gave me a threader to use. Started going to work and all seemed good until the tool snapped. He tried to drill it and put a tap into it and that snapped too. So then he just went to town with a torch and burned it all out so there's a larger all messed up hole where my original threading used to be. I wasn't there when he was doing that or else I would have stopped him. So what's the best course of action now? Try to fill in the hole and drill a new threading? This is pretty far outside my realm now.

 

I just left my sway bar off. Better for offroad. You don't have to have it. Are you just trying to bolt your sway bar back on?

 

It was a threaded hole in the frame and a bolt went into it so I'm not sure how welding on a nut would work exactly.

 

Bolt the sway bar back on and bolt the mount for the remote reservoir in as well. It just irks me that there's a messed up burnt hole in my frame now. I mean it's barely bigger than the original bolt hole but still.

 

There's two holes for the sway bar mount. Just use 1 of them for your remote resi mount or use a clamp. Clean everything off, spray some flat black paint on it, no one will ever know. This will only work though if you DON'T reuse your sway bar.

 

How different does it drive without the sway bar?

 

You honestly won't even know its gone unless you are driving like 55mph and jerk the wheel hard to one side or the other, which isn't a good idea anyway. Most guys who offroad a decent amount take it off. I'm sure some die-hard people swear against it, but i've had mine off for over 30k and have never had issues.

 

on the street around a corner, big sway, just letting you know....going slow crawling over rough terrain, not a problem...the problem you have can be fixed by a reputable shop, don't let the grease monkey from the post autoshop touch it again...at least it wasn't an something more important to the operation of the suspension...

 

IMO it drives better and i only have 5100's with stock TRD OR coils at 1.75 setting. Smoother and allows the suspension to do its job. Yes there is more body roll but its not like OMG IM GOING TO ROLL THE TRUCK bad, its only a little more.

With icons and the stiffer springs that come with them your fine. leave the swaybar off for a bit and i bet you never put it back on.

 

I agree

 

40 mph is enough to do it:

https://www.youtube.com/watch?v=IRT33AYBN1w

 

Too logical bro , gotta join the herd

 

Toyota engineer, insurance people, and I would have to disagree with you

Exactly, a foolish and dangerous mod to do

 

Toyota police is here.
Time for me to drive my dangerous opinions elsewhere. OP, all i can say is try it for yourself and see if you like it. If you don't feel safe or feel uncomfortable without it, find a way to weld a new nut on and bolt the swaybar back on. Otherwise, enjoy a better off road rig without it.

 

Key word right there. "off road"

 

That guy has no business working on machines of any kind.

 

In Washington State a front swaybar isn't required but there is a performance standard.

A motor vehicle must be capable of stable, controlled operation while traversing a slalom-type path passing alternately to the left and right of at least four cones or markers arranged in a straight line and spaced sixty feet apart at a minimum speed of 25 mph.

If it will do that without the swaybar you should be good to go.