True...but i'll try and get the nut off tomorrow and I'll take it from there, I'm at work now so I can't really try anything atm but i'll get some pictures for you guys so you can see exactly the situation!

 

I made a crude drawing in paint to illustrate how I would do it:



Cut down the middle of the nut, then chisel up the center of the cut, this will get the nut to open up, you should get an idea of where your spot welds are at that point. Either cut the spot welds, chisel them off, or bend the cut section of the nut back and forth to fatigue the spot weld. Just my perspective. Good luck.

EDIT: Do this after you drill the bolt portion out as big as you can, without wallowing out the hole too much...

 

With a sawzall? Hm, seems a bit tricky trying to get it centered but will have that in mind!

One thing i'm worried about with your procedure - how will that affect the possibility of me getting an easy out in the bolt and getting that out when the nut is cut off?

And still, welded spot should be seen and I didn't see any...perhaps I'm in luck or just plain blind

 

I think you misunderstand. You won't be using an e-z out at all. Drill as much of the bolt out of the nut that's welded in place. Don't worry about the threads on that nut at all. You are going to destroy that welded nut anyhow. The reason for getting as much of the bolt out of the hole is so you have less material to cut through when you split the nut. Once you drill your hole big enough, place your sawzall blade up through the access hole you cut. Cut the nut as I illustrated, as much of it as you can, it doesn't need to be dead nuts in the middle, just so you can split the nut in two. Then chisel from the cut you made in the nut. The nut should unfold like a clamshell. That's how you'll find the spot welds. Cut or grind those spot welds away and discard the nut pieces and use new hardware. A better diagram:

 

Ah yes. I did misunderstand you there but the plan sounds good, to be honest but as all things, it'll probably be harder to do than the drawing and your description suggests

But, won't it be a good idea to try and split the rest of the bolt in the middle as well? Trying to release som pressure with a chisel in the middle and trying to wedge it "open"?

 

LOL, yeah it all sounds good on paper, actually doing it will always be harder than it looks...you can try splitting the nut with the bolt still there, but it would be more difficult because you have to cut more material away. If you drill out the rest of the bolt, you will have to cut less material when you split the nut. Make sense?

EDIT: Take pictures and post them up. I can then use paint to give you a better idea of what to do.

 

No offense, but this is getting kinda ridiculous dude. Put a friggin wrench on it with a cheater bar and break the damn thing off already.

 

Seriously? If you don't like it - why reply? I really don't people complaining in threads about such things.

On to the topic - I tried the things you suggested ronin except they didn't work - at all. The blade is way thick/wide (whatever) to fit so I can't cut the nut in half....I got a wrench on the nut, but it just rounded the corners so it's unusable now.

I cut up more of the box now and i'm seriously just thinking of getting the jeep running so I can take it to a shop and just fu****ing throw money at somebody with access to electricity to fix the crap. So freaking tired of ****ty engineering and this thing holding me up.

Thanks for the help though.