Ok, I got a quite a bit done yesterday and I should get more done today. I started with getting the factory clip off the frame table and then putting the two rearends I have all on a rolling pallet.
Then I started working on cutting the small pieces that go from the front clip out to the main rails. The front clip is 25" wide overall where the factory frame is around 29"
The main rails on this truck are 34" wide overall where the factory frame is about 40" wide. I wanted ths frame to be narrower so the slope in the floor from the doors to the frame is not as much of angle up hill. I cut the main outside rails (93") and clamped them both in place and welded them in.
Then I added some 1" square tube braces to the middle and the back and concentrated on the front. The next piece in the front was the down pieces where the steering box and idler arm mount. These required drilling 3/4" holes through both pieces and installing some crush tubes. These have to be welded in pretty well because they hold the steering box on one side and the idler on the other. But also they need to not leak air.
I put a flat piece of steel inside and outside the top rail and clamped them all together. Then welded the right hand side down tube on. Then I clamped the other one on and clamped a 2x3 angle across the top so the angle was the same across both side. I measured up from the table to make sure they were both the same height.
Then I welded on the front stubs. These are level and parallel to the frame rails. I then cut small round holes in the bottom front of these stubs to allow air into the front drop section. Then I made caps for the rails and tacked them on. Notice everything is beveled for a good weld.
Then I made the drop section on the table and clamped it on and welded it all up.
That was all I had time for yesterday. I was also helping my kid pull a 460/C-6 from an 85 Ford truck. It's going in his 66 F-100. I will have to help him more today. He has two friends helpin but I'm certain none of them have pulled a motor before.
Since I won't be able to rip the Sportage motor out while they occupy the driveway I will work on the back of the frame today. Can't make any control arms until I order some DOM tube and some bushings. I might test mount the steering box just for giggles.
So I will work on the rear section and help the kids. More to come.