Repair protruding frame slot?

[Shimmy]

i'm installing my LCR/JD 20gal tank. i've removed my stock 77 tank and noticed the passenger side hole slot is protruding out. i believe i'll need to push this back in somehow or repair it to accommodate the JD tank mounts to the frame.

does anyone have any tips or advice on how to do this? i have limited tools available when it comes to repairing thick metal like this. one thought i had was to cut it out further and then weld in a sheet of metal flush but i was hoping i didn't have to do that since i dont know how to weld. maybe a BFH? 3lb?

thoughts?

 

[Steve83]

Hammer or jack should work.

 

[DirtDonk]

Can’t say I’ve seen one like that Shimmy. But it does look relatively straightforward, other than having to repaint it.
Too bad it wasn’t noticed earlier, that’s a minor part of it the overall repair.
I think you’re onto it with a BFH. And since it’s in an awkward position, maybe a heavy steel rod or big punch with a wide flat tip.
Or, in lieu of the BFH, you might try a ball peen hammer that’s a more manageable size.
Bodywork ends up being a series of small tap, tap taps. But as thin as our frames are, they’re still much thicker than sheet metal. So you do need a little more heft to get it started.
If you try to tap tap tap, it’ll still work, but it takes a lot longer.
Some smacks and taps should it should put it back in place.

Or like Steve said, a jack might just work.
Since it looks like most of the weight the the vehicle is all back together, it might just push right back up in with a jack.

 

[Shimmy]

Hammer or jack should work.

i tried a jack and it just lifted the truck. i'll admit it was a 75% effort on my part. i'll try it again today.

 

[1969]

Heat it with a torch, and hit it with a bfh.

 

[73azbronco]

inductive heater, my newest cool toy, and hammer. Doesnt tank hanger go there or does it use round hole?

 

[jamesroney]

i'm installing my LCR/JD 20gal tank. i've removed my stock 77 tank and noticed the passenger side hole slot is protruding out. i believe i'll need to push this back in somehow or repair it to accommodate the JD tank mounts to the frame.

does anyone have any tips or advice on how to do this? i have limited tools available when it comes to repairing thick metal like this. one thought i had was to cut it out further and then weld in a sheet of metal flush but i was hoping i didn't have to do that since i dont know how to weld. maybe a BFH? 3lb?

thoughts?

Get a block of 1/2-3/4 inch thick steel about 2 inches x 2 inches with a 1/2 inch threaded hole in it.
Place it in the frame thru the bumper opening.
thread a bolt into the plate with a big washer.
tighten the bolt. It will flatten the area exactly like you think it should.

If you are not a metal fabricator, and you don't have a lot of excess material lying around...

1. Get a harmonic balancer bolt and heavy thick washer from a small block Ford.
2. Take some electrical tape and tape the bolt to the box end of your 15/16 wrench. Tape the washer to it as well.
3. Fish the wrench / bolt / washer assembly into the hole from the bumper end.
4. Take another heavy washer (or plate, or whatever...) and get a 5/8-18 hex nut. Sandwich the frame between your bolt and nut.
5. Tighten the bolt. It will squish the frame like butter.

 

[DirtDonk]

Although I'm a fan of hammers, I always love a good load and leverage, torque and threads story!
Squeeze the metal until it whimpers back into it's corner.

Paul

 

[Revelation]

Once back in place I would weld the stress cracks that formed when it was pulled out, Small cracks can become major issues down the line.

 

[OlliesBronco24]

Anyone know what could cause this? I think I have the exact same thing on my frame now that I think about it.

 

[Shimmy]

Anyone know what could cause this? I think I have the exact same thing on my frame now that I think about it.

my guess is that it was caused by someone using the slots as tie down point and ratcheting it down too much

 

[1969]

my guess is that it was caused by someone using the slots as tie down point and ratcheting it down too much

Or a recovery point as well..

 

[Steve83]

i tried a jack and it just lifted the truck.

Set the jack so it's only pushing 1 side of the slot at a time.

 

[jamesroney]

Anyone know what could cause this? I think I have the exact same thing on my frame now that I think about it.

Small bolt head on a big hole with a loose bolt holding up a 23 gallon fuel tank for a long time.

Tie downs and recovery points usually yield in a direction of travel. These points show a downward trajectory, with stress fractures typical of cyclical loads.

Any fastener that loads the frame should be tightened against a positive stop. Those gas tank hangers drive me bananas.

 

[Shimmy]

Small bolt head on a big hole with a loose bolt holding up a 23 gallon fuel tank for a long time.

Tie downs and recovery points usually yield in a direction of travel. These points show a downward trajectory, with stress fractures typical of cyclical loads.

Any fastener that loads the frame should be tightened against a positive stop. Those gas tank hangers drive me bananas.

in this case i'm not sure that how this happened. i'm 95% certain this is an original tank.

what's odd is the driver side slot is actually poked in a little

about to try your suggested sandwich idea

 

[jamesroney]

Small bolt head on a big hole with a loose bolt holding up a 23 gallon fuel tank for a long time.

Tie downs and recovery points usually yield in a direction of travel. These points show a downward trajectory, with stress fractures typical of cyclical loads.

Any fastener that loads the frame should be tightened against a positive stop. Those gas tank hangers drive me bananas.

Fair enough. Then I'm gonna vote with you or @1969

Best of luck on the fix.

 

[Shimmy]

@jamesroney that worked pretty darn good!!

thanks you!

 

[DirtDonk]

in this case i'm not sure that how this happened. i'm 95% certain this is an original tank.

What exactly are we looking at shimmy? Got a picture of the underside from a different angle? Maybe even from a little further away?

 

[Shimmy]

What exactly are we looking at shimmy? Got a picture of the underside from a different angle? Maybe even from a little further away?

they were discussing how the slot hole got pulled out.

anyways, got it all fixed! thank you guys!!

 

[DirtDonk]

Thanks. I meant a picture of your original tank mounting.
But I was neglecting to realize in the spur of the moment, that of course that tank is no longer in place. I was just curious how it mounted in that hole.