i messed up
i messed up 
03-18-2007, 07:38 PM
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03-18-2007, 07:58 PM
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03-18-2007, 08:31 PM
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That's a bummer. I guess you didn't have the jigs that come with most of the kits?
After I had mine welded in, I had an idea that might be helpful for your fix. In my opinion, it can be difficult to get the holes all lined up even with the jigs. Keeping everything in the right position once welding starts doesn't make things any easier.
I thought it would make sense to pre-weld the bushings to a plate. It would look like a "T" when done. One would have to match the angle of the frame to keep things parallel, but then the actual frame holes would not have to be that precise. One could actually have some room to move (fore and aft) and the plates (being exactly the same) would keep things aligned.
Like this:
Position new "T" part into frame. Bushings would be in exact position and wouldn't rely on a jig hole or the precision of your hole saw/ plasma cutter/ torch/ BFH.
As such:
Then place your second pre-drilled plate on the inside and weld the bushing to it, as well as welding plate to the frame.
TaDa:
My thought was all the precision fab work could be done in a more comfortable and precise work space instead of upside down and under the truck. Also, the plates would add significant strength and allow both sides to align perfectly.
It would be nice if one of the pre-fab kits came with bushing already setup like this so you could make a much rougher frame cut yet still have a more accurate and strong finished product. I am sure a production fab company could really get the angles and plates to match perfectly and make the home fab step that much easier.
After I had mine welded in, I had an idea that might be helpful for your fix. In my opinion, it can be difficult to get the holes all lined up even with the jigs. Keeping everything in the right position once welding starts doesn't make things any easier.
I thought it would make sense to pre-weld the bushings to a plate. It would look like a "T" when done. One would have to match the angle of the frame to keep things parallel, but then the actual frame holes would not have to be that precise. One could actually have some room to move (fore and aft) and the plates (being exactly the same) would keep things aligned.
Like this:
Position new "T" part into frame. Bushings would be in exact position and wouldn't rely on a jig hole or the precision of your hole saw/ plasma cutter/ torch/ BFH.
As such:
Then place your second pre-drilled plate on the inside and weld the bushing to it, as well as welding plate to the frame.
TaDa:
My thought was all the precision fab work could be done in a more comfortable and precise work space instead of upside down and under the truck. Also, the plates would add significant strength and allow both sides to align perfectly.
It would be nice if one of the pre-fab kits came with bushing already setup like this so you could make a much rougher frame cut yet still have a more accurate and strong finished product. I am sure a production fab company could really get the angles and plates to match perfectly and make the home fab step that much easier.
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