g-man
SILVER Star
I bought a set of C channels from Trail Tailor and contemplating this job. Waiting for some nicer weather. Looks like I need to ...(EDIT..I am editing and deleting steps as I work through this)
1.(EDIT) Use a cutting torch or air hammer (with several spare chisel blades) and Cut, grind drill or drive out any rivets that hold the c channel to the outer frame and not holding any other support or mount. Removing the head of the rivet will NOT loosen the remainder squeezed inside the frame. Plan on cutting the head off and driving the rivet body out of the frame. I spent hours drilling and grinding only to realize the air hammer was MUCH quicker.
2. remove the spare tire and unbolt and remove the cross member. 14mm nut and bolt
3. unbolt the exhaust hanger at the driver side from the frame. 12 mm
4. Cut, Grind and or drill/drive out the body mount rivets. Not necessary to support the body as there are body mounts rearward near the rear bumper on the frame and aft of the c channel that will hold the body in place. It is a good idea to check the body mounts forward and rearward of the C channels to make sure they are intact and will hold the body. My body mounts never let loose from the frame even after all the rivets were removed.
5. jack the rear of the truck up put the frame on jack stands forward of the rear axle.
6. With the axle hanging and wheels off the ground, remove the rear spring from the shackle
7. remove the shackle from the shackle mount
8. remove the shackle mount from the frame cutting/grinding/drilling out the rivets
9. drive out any remaining rivots and remove the old c channels. Use a step drill to open up the rivet holes to accomodate the Trail TAILOR bolts. DON'T accidently drill out the mounting holes for the exhaust hanger...these are threaded holes but look much like rivet holes.
10. cut and weld new metal into the existing outer frame, also a good idea to weld around the body mounts and shackle mounts.
11. Drill out with step drill or gradually larger drill bits all holes so they can accomodate the new bolts. Wire brush clean treat rust and paint the frame and and the c channel
12. bolt the new c channels in place while bolting the shackle mounts and body mounts and cross member too. It is important to get both c channel sides in place along with the cross member BEFORE putting any bolts in.
13. install the exhaust hanger bracket
14. reinstall the shackles and leaf springs.
Removing the gas tank will help you to access the top of the frame (for grinding sanding rust etc) Will give you more headroom. Will make it safer as your going to throw sparks around. I did not remove my tank...but I know my truck and it is not leaking gas anywhere and I used a board above the frame and below the tank to help divert sparks.
1.(EDIT) Use a cutting torch or air hammer (with several spare chisel blades) and Cut, grind drill or drive out any rivets that hold the c channel to the outer frame and not holding any other support or mount. Removing the head of the rivet will NOT loosen the remainder squeezed inside the frame. Plan on cutting the head off and driving the rivet body out of the frame. I spent hours drilling and grinding only to realize the air hammer was MUCH quicker.
2. remove the spare tire and unbolt and remove the cross member. 14mm nut and bolt
3. unbolt the exhaust hanger at the driver side from the frame. 12 mm
4. Cut, Grind and or drill/drive out the body mount rivets. Not necessary to support the body as there are body mounts rearward near the rear bumper on the frame and aft of the c channel that will hold the body in place. It is a good idea to check the body mounts forward and rearward of the C channels to make sure they are intact and will hold the body. My body mounts never let loose from the frame even after all the rivets were removed.
5. jack the rear of the truck up put the frame on jack stands forward of the rear axle.
6. With the axle hanging and wheels off the ground, remove the rear spring from the shackle
7. remove the shackle from the shackle mount
8. remove the shackle mount from the frame cutting/grinding/drilling out the rivets
9. drive out any remaining rivots and remove the old c channels. Use a step drill to open up the rivet holes to accomodate the Trail TAILOR bolts. DON'T accidently drill out the mounting holes for the exhaust hanger...these are threaded holes but look much like rivet holes.
10. cut and weld new metal into the existing outer frame, also a good idea to weld around the body mounts and shackle mounts.
11. Drill out with step drill or gradually larger drill bits all holes so they can accomodate the new bolts. Wire brush clean treat rust and paint the frame and and the c channel
12. bolt the new c channels in place while bolting the shackle mounts and body mounts and cross member too. It is important to get both c channel sides in place along with the cross member BEFORE putting any bolts in.
13. install the exhaust hanger bracket
14. reinstall the shackles and leaf springs.
Removing the gas tank will help you to access the top of the frame (for grinding sanding rust etc) Will give you more headroom. Will make it safer as your going to throw sparks around. I did not remove my tank...but I know my truck and it is not leaking gas anywhere and I used a board above the frame and below the tank to help divert sparks.
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