I've had my samurai since 1998 or so and it continues to be a GREAT rig.
It started as my college cruiser and rapidly evolved into a serious little offroader.  OK I confess, some college financial-aid got used to begin building her back then.  
Anyway, 13 years later, after numerous flops & at least one full rollover, GPS challenges, leading some Powerfest events, a couple trips to Moab, races at Suver International Raceway and Famous Dave's Offroad Park, and many other NW adventures, she's still going strong...
After recently selling my FZJ80 Land Cruiser to fund my financial-freedom-plan, I began daily driving the sami again.
It's been a pleasure to update her with some goodies and get back into the seat full-time.  I've enjoyed it way more than anticipated.  But I've had a few technical difficulties of recent, and thought I'd share my endevours, for entertainment purposes at the very least...

First, the transfercase bearings decided to give up the ghost.  This took some time to diagnose but worked out well in the end.  Here's a link to the thread, located on our local 4wheel drive club webiste: (lots of pics and discussion)
http://www.midvalleycrawlers.com/Forum/forums/thread-view.asp?tid=1648&start=1

Second, a quick valve cover gasket change which turned into a disaster. It required a MacGyver fix (to get home), which has become my permanent fix... for now at least:  (again, lots of pics and discussion)
http://www.midvalleycrawlers.com/Forum/forums/thread-view.asp?tid=1662&posts=37#M21263


Oh, and here's a recent picture of the old girl:  (Hope you enjoy the threads I linked)

good luck with your financial peace. i'm going to see Dave Ramsey in April (I think it is). will you be there?

Thanks Jluck.  I've listened to Dave Ramsey on the radio and read some of his stuff.  Very inspirational.  I'd like to see one of his seminars or "universities" as he calls it.  Is he coming to Oregon in April or something?

Thanks Jluck.  I've listened to Dave Ramsey on the radio and read some of his stuff.  Very inspirational.  I'd like to see one of his seminars or "universities" as he calls it.  Is he coming to Oregon in April or something?

yes sir I think its like the 9th. I would have to look at the tics

Dave Ramsey is coming to Kansas City in March.

I have an autographed Dominos delivery jacket from his last visit - I hope to get my Pizza Hut delivery jacket autographed this time.

I think it is rebuild time for my virgin '88 t-case...

Back on the subject of the valve cover bolt.... If you would get the remaining broken bolt piece from the head it can be repaired without welding. There is a composite epoxy called Gray Iron that can be used to rebuild the damaged area. This compound is much like epoxy although it has finely ground metal shavings in it. As a younger man I was playing around with it and sealed a water port in a SBC intake once as a test. Once it sets up you can file, grind, drill, tap, etc.

Here is a link to some compounds that may be comparable and do the job for you. FMSC  

Back on the subject of the valve cover bolt.... If you would get the remaining broken bolt piece from the head it can be repaired without welding. There is a composite epoxy called Gray Iron that can be used to rebuild the damaged area. This compound is much like epoxy although it has finely ground metal shavings in it. As a younger man I was playing around with it and sealed a water port in a SBC intake once as a test. Once it sets up you can file, grind, drill, tap, etc.

Here is a link to some compounds that may be comparable and do the job for you. FMSC  

That's a great idea!  Thanks for the info and link!

I was thinking bout your valve cover some more and here are a copule  of other fix ideas...


DURAFIX

HTS 2000

Both of these can be done with a hand held propane torch. They both claim to be able to build the material up. If this can be done then you could drill and tap the area and be good to go.

They are also both realitively inexpensive fixes and if the stuff works up to claim then it would be a handy item to have around.

I was thinking bout your valve cover some more and here are a copule  of other fix ideas...


DURAFIX

HTS 2000

Both of these can be done with a hand held propane torch. They both claim to be able to build the material up. If this can be done then you could drill and tap the area and be good to go.

They are also both realitively inexpensive fixes and if the stuff works up to claim then it would be a handy item to have around.

I really appreciate your continued ideas and help!  
My temporary fix is holding for now but I plan to do a better, more permanent repair later, maybe this summer.
Your ideas are giving me hope that this can be done fairly innexpensively.  And even if it doesn't work, I can continue to use my improvised valve-cover hold-down system.