I could simply make the brace, but I knew I wanted to add some frame stiffeners to the stock rails. I already had some on the center portion installed about 10 years ago when I swapped to long arms. So I figured since I had it apart, weld these on
To here
The additional 3/16” thickness causes issues with the trackbar because it spaces out. Fortunately my Tb bracket has slotted holes to accommodate this. But I wanted to install these first before doing the brace, because I didn’t want to slot the brace, I wanted it to be exact fit. So I had to do the frame rails first.
This required me to finish removing the old stock control arm brackets which I had hastily cut off 10 years ago. Bought a cheap spot weld cutter and cut 25 spit welds to remove the last bits so that I could install the stiffeners correctly. To do so, I had to remove the lower control arms, which of course led to cutting one of the bolts that had seized inside the bushing. And of course that bushing is an oddball size, and the manufacturer has since discontinued my particular kit, so I spent a few hours hunting down the right size online. Of course it doesn’t come with the inner sleeve, so I had to hunt those down separately. One of the original flex joints was pretty warn out, and I had already swapped the other to a Johnny joint, so I figured may as well make them match.
Then after some reading, I decided I didn’t want to use flux core and I’ve been meaning to get a bottle of gas for my Hobart. I’ve learned every new project should require a new “tool” in order to justify it to the financial manager, so picked up a bottle of gas and some 0.023” wire and tips from the local welding supply. 125’ bottle filled was $245, I own the bottle, and they will refill for $45. I guess those are decent prices, don’t really know.
I have some days off next week, so I’ll be cleaning up the frame rails (the entire body is galvanized so you have to get to clean metal to avoid the toxic gas when welding galvanized) and then welding next week. Then I can reinstall all of the new parts/refurb bits, and actually start on the entire focus of this venture, which is building the trackbar brace. More pics next week. The End.
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