Progress has been slow the last two weeks, but I've got most of the rear frame top coated and looking good, at least for a truck that spent 22 years in the salt. I also got the new spare tire cross member in last night. Went in fairly easy, I was able to get it into place mostly by hitting it with the palm of my hand. Some firm, but fairly light taps with a rubber mallet got it in place the rest of the way. All but one of the bolt holes lined up perfectly. The one that didn't I attempted to move, but it just ended up twisting the frame rail instead. Since I didn't like the idea of putting the frame in tension, I just filed down a small bit of the cross member bolt hole (less than a 1/16th of an inch). I wasn't a fan of doing that either, but it bothered me less than putting torsional strain on the frame. Anyone with a background in structural steel design feel free to correct me on my methods, I haven't had to deal with that since college. Anyway, here's some pics.
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Shame the new cross member makes the rest of my pitted up frame look like junk, but short of putting a new frame under the truck, it is what it is. I'll clean up the paint that dripped down on the exhaust.
Here's a list of things I'd like to get done before I send it in for body work and paint.
Reinstall the other spare tire brackets
New leaf springs/bushings
Change rear diff oil/inspect gears
New U-joints
Install new gas tank/fuel lines
Finish cab metal repairs
Finish bed metal repairs
Replace driver door
Fix metal on passenger door
Weld shut holes drilled into back of cab (no idea why those are there)
Replace front quarter panels
Install a new rear bumper, although this doesn't necessarily need to be done yet
Radiator bushings while quarter panels are off
Either new rear window, or get the existing one re-sealed. I'm partial to the rear slider. I'll have someone else do this.
Other things I will have a someone else do, paint/body work, new tires, tire alignment, and patch a rust hole in the drivers side frame, right near the joint where the boxed section meets the C-channel under the firewall.
Not a short list, but if I put in the hours, I think I can have most of this done by late spring. I work two jobs and prioritize family and friends over the truck (although I'm holding off on dating again until this thing is back on the road...probably), so work on this can be sporadic at times, but it will get done.