Another Jeep J20 Build

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The frame rails are too far apart. There is usually some variation between the frames, some are a bit tight, some loose but 7/8” is too much. I could simply install the crossmember and squeeze them together as the attaching bolts are tightened but this would impart additional and continuous stress on the already crack prone flanges of the crossmember.

I’m not sure when or how this occurred. It may have happened when I cut the original rusted section out for the previous repair. I recall hearing a rather loud pop at the end of one of the cuts. Some spreading may have also occurred when I welded the new section on.

Notice the series of paint chips in the flanges of the frame rail. These were caused from heavy hammer blows while the squeezing was taking place. This hammering helps to reduce the spring back of the rails when the force of the load binders is released. When hammering I alternate blows from side to side. Completing all the blows on one side first and then the other may cause an uneven balance of relief as the first side will likely have more stress during hammering than the second.

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These are the front brake caliper mounting brackets. As often happens, the shield has rusted.

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The tooling I will use to make new ones.

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There are two flanges on this piece, one inboard and one outboard.

I start with a 2” wide strip of sheet steel placed in the form. Here I have started to tip the outboard flange.

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The flange is complete.

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The inboard flange. I made a series of relief cuts because unlike the outboard flange this one is being shrunk.