I tried to get the expansion plugs locally and found the following:
O'Reilly Auto - $2.99/ea (1 in stock)
AutoZone - $2.99/ea (1 in stock)
Napa Auto - $4.59/ea (1 in stock)
ACE hardware - $4.00/ea (6 in stock)
O'Reilly and AutoZone were Doorman 1" - 1-1/8" (25mm - 28mm) Expand-Tite Rubber expansion plugs (#02600)
. Napa and Ace sold them un-packaged. Ace hade them in a pull out drawer on the nuts & bolts isle.
I got one from each of them because I went to Ace last and only planned on making 4. I got the following from Home Depot:
5/16" x 3-1/4" eye bolt w/ nut - $0.63/ea
5/16" tee nuts - $1.18/4pk
After building and testing those 4, I decided I needed at least 4 more. I decided this time to search online for a cheap price and found the exact same Doorman plugs cheaper:
- $2.56/ea (+$5.45 priority mail S&H for 8 plugs)
I got 8 more eye-bolts and 2 more packs of tee nuts from Home Depot for $7.90 making my total for these 8 tie-downs $33.83 after tax and shipping.
Also, I made mine just like @guy48065 did in the first post. Here is a list of the steps I took to build them:
1 - Remove the hardware from the plug. Keep only the rubber and the larger washer.
2 - Drill/ream the hole in the plug with a 3/8" drill bit. This isn't required, but will help keep the plug from expanding from the tee nut.
3 - Cut the barbs off the tee nut, leaving only little nubs. When the tee nut is used with the full barbs, it expands and makes it difficult to insert the finished tie down.
4 - Thread the nut all the way up to the eye. I've seen some made without this nut, but I think that might make it harder to hand-tighten from above.
5 - Put the eye bolt through the flat washer, then the rubber, then into the tee nut. Had tighten until the tee nut has set into the plug.
6 - Insert into a lock-and-ride hole in your RZR and hand tighten. I tightened them as much as I could without tools and they were pretty stable. I gave them all another 1/2 to 1/4 turn with a screw driver through the eyelet and had no fear of damaging the plastic on my RZR. With 4 of these and some bungees I kept my cooler and tool box in place without incident for 2 days on some fairly rough Uinta trails.
I've seen some of the ready-made versions of this plug using a fender washer and (nylon lock?) nut on bottom. If I were leaving these in semi-permanently, I would think that would give the best hold and stay power.
I also like the hook idea, but think I may just cut a 1/4 inch from a couple of my eye bolts where the bend returns to the eye or spread them out a little. That should give me enough of a gap to slide bungees or straps into the eye without having to feed them through.
Parts for 8 tie-downs (1 extra eye-bolt & pack of tee-nuts):
Rubber plug drilled out and barbs on tee nut clipped off:
The tee nut in the first plug has the full barbs still, the second one has them clipped. You can see how much the barbs distort the rubber and makes them harder to insert:
Close-up of a tee nut with the barbs cut off. I just used red-handle tin-snips:
My 8 newest complete tie-downs.