Welding in new box frame

[jim land]

They probably use rivets on those space ship , bolts are so dangerous and unsafe 😉

 

[DangerNoodle]

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 over the place when driving and turning the wheel. Use the search function, this has been done b4. .

I think using a grinder is quicker and easier to remove the rivet heads.

I like an oxy torch with a scarfing tip for rivets and annoying brackets. It will peel them right off. Quick brush with a flap wheel to pull slag, and then air hammer out the rest.

I would weld that section back in, filling the rivet holes and shaping the bead to look like a rivet, and fishplate the rest.

 

[V8FJ4078]

It looks like you got the frame almost as hot? Is that sand blasted?

Yes it was sand blasted.
We did heat some up again once in since they cool quickly and working with them hot takes some time to be careful too