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  1. pb4ugo

    Welding in new box frame

    Your way over thinking this. 1 person could probably spread the rails while someone else is installing the crossmember.
  2. pb4ugo

    Welding in new box frame

    You can measure if you want. There's 12 rivets locating that crossmember.
  3. pb4ugo

    Welding in new box frame

    I'd wouldn't want a any bumper welded to my frame either.
  4. pb4ugo

    Welding in new box frame

    He'll likely have to remove the bumper to spread the rails apart to get the new crossmember in. I used a high lift jack to spread them apart. I didnt take much force. He should be fine. Like you said the rivet holes should square the frame. It is a high flex area, the frame rails move all...
  5. pb4ugo

    Welding in new box frame

    I grinder or drill to cut/grind the rivets heads off and a punch to pound the rivet shanks out.
  6. pb4ugo

    Welding in new box frame

    I just noticed it's for a later model frame.
  7. pb4ugo

    Welding in new box frame

    https://forum.ih8mud.com/threads/fj40-cross-member.1280730/ I'd probably use the one you have if its not cut up or not structuraly compromised. Just remove the rivets and clean it up and install it.
  8. pb4ugo

    Welding in new box frame

    The PO hacked in a sag box on one of my 40's and had to deal with the same thing. I tried patching it a few times. Eventually I replaced the whole crossmember and went to scout steering. That portion of the frame is a high flex area. Even removing the box and patching the crossmember...
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