Propwash
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Prop,
I'm fighting with the rear x-member on my 'runner. I've already run into a stamping problem; there's only one bumper hole on the bottom edge. I'm using AMD parts and have already emailed Jeff to find out what to do about the mis-stamping.
I also noticed what you said about the top edge being narrower. Being the genius that I am, I drilled some of the welds out from the top thinking it'd be easier to drill and weld standing up instead of laying on my back. Now I've got about a dozen holes to fill because the new part doesn't cover the holes.ops:
If you've got any other tips from your experience installing yours, I'd sure appreciate hearing them. I'm installing all five parts, side to side. If it wasn't for threads like this one I probably wouldn't have started trying to do the welding on my car. So I'm not entirely sure if I should thank you or hate you :icon_lol:
But seriously ... :notworthy: thanks
LOL....Sorry Bob...don't shoot the messenger. :grin: Glad my thread got you to grab the bull by the horns and take on your project. That's what its all about.
Sounds like a pretty good screw up by AMD. You should have 4 tabs on the bottom lip. 2 of them line up with the rear of the frame rails. The other two line up with the outer support of the shackle mounts to the outside of the end of the rear rails. I guess the first question I have is; is the tabs there, but there is no holes or is there none of those other three tabs at all? As far as the other holes, they're centered just like the one you have. If there is no tabs, duplicate the measurements of the one you have, get the x-member centered in place, drill the holes in the new tabs then weld the new tabs in place. I would use 16GA material.
As you found, you're better off welding inverted when welding the x-member top lip to the bottom side of the trunk pan. I guess with the "extra" twelve holes you have, get yourself a chunk of copper to use as backing (the thicker the better), place of the backside whatever way you're welding from and fill in the holes. The weld doesn't stick to the copper. Sometimes it can stick just a tad, but wiggle it a bit, it usually comes right off.
I did drill the holes for the plug welds before installing the x-member and then positioned in place. I used #10 Sheetmetal screws, drilled a hole through both panels and then used the sheetmetal screws to pull the two panels together as tight as possible. Still had to use an Oak dowl and a hammer to manipulate that lip to fit tight as possible against the bottom side of the trunk pan in places. Next filled in the plug welds (inverted) and the small holes from the screws. I did have an issue with the top lips of the x-member reinforcement plates tucking up in between the rear tailight panel. Had to shave about 1/8" off that lip so they would tuck up behind the panel.
The x-member extensions did not seat the best against the trunk extensions. The factory had spot welds that welded from the outer lip of the x-member extension to the trunk extensions. I had to make relief cuts on the corners of the lip off the x-member extension, tap into place and then fill in the plug welds, I also fillet welded between that x-member extension and
trunk pan extension interface. One other thing I did to add to beefing it up back there is I ran a full fillet weld along the outside edges of the reinforcement plates instead of the small tac's.
To line the x-member in place, I used the notch in the tail light/fill panel as reference. I found the center of the hole for the gas tank filler neck, marked it, then ran a plumb bob straight down from that notch in the tail light panel, lined the mark I made on the hole in the x-member with the string from the plumb bob, then secured in place.
Other than that, no real issues....unlike your situation. Pretty straight forward stuff. I hope AMD/Jeff takes care of you. He's a great guy and I can't see him not making it right for you one way or another. Any other help I can offer, please don't hesitate to ask. Best of luck on the rest of the x-member project on your bird Bob.
