Going to start a frame up build very shortly.  The frame that I acquired is a 1987.  The foot peg bolt holes on the stator side have been drilled out and larger bolts have been installed with nuts behind them.  I want to add a lot of bracing to this area and also the cushion lever similar to the 1988 and newer models.  My question is, what is the best way to fix these?  I don't know if I will leave enough room to get the nut back on on the back side with my added bracing.  The clutch side bolt holes seem ok when I use longer bolts.  Any ideas would be appreciated. Also going to gusset up the frame really good.  Have been browsing the threads on frame gusseting and have some ideas.  Thanks. 

Can you not just weld the nut that is already there to the frame?

Being of economy size, I have snapped a few bolt sin my lifetime, Think OEM is 10mm, I went and drilled them out fro 12mm and went with longer thread grade 10.9 chromed Allen bolts  ( i use anti seize with  lock washers , I check the bolts now and then to see if they are bending, that grade 10.9 is strong chit, plus with threading it longer you get a better bite. ( you will have to drill the pegs holes to 12mm also.

Well, those are 7/16 bolts through there.  I tried a M12 tap and it is too loose.  So more options would be to tap it for 1/2-20 or find a really deep nut and weld it on to the back side of the frame and tie it in with all the frame bracing.  These foot peg areas and cushion lever area are going to get really beefed up.   Still debating on what will be the best.   

Well, unfortunately the holes in the frame are too big for the 29/64 drill bit to drill anything out.  SO I am back to welding a deep nut on the back side of the frame and using 3" long bolts.  It should look fine when its done..  As long as it stays right-side-up