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Old 01-03-2005, 10:34 AM's Avatar is offline Moderator
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The way I like to do it is cut off the bolt head first. Then taper the square shoulder on all 4 sides so when you put it in the bumper there is a nice V-trough on the front side to fill with weld. Weld it in just proud of the face of the bumper, filling the V-notches with weld penetrating to the back side of the bumper. This procedure literally makes the head of the bolt part of the bumper, yet lets the shank of the bolt under the square maintain it's fillets and stress relief as designed by the bolt engineers.
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