Cutting some Cross Support Bed Welds

[kizer]

I'm in the process of removing and painting all of my bed supports and I got to the last one being the rear one where the tail gate is. I took out all 4 bolts on both sides and then realized there are a few welds that appear to need cut and well I cut them. However I think I kinda screwed up.

The cut on the top was easy, but I did make it a bit sloppy, but I'm sure I can re-weld it later and smooth it out. Then I cut the bottom cut and it looks like I cut into the bed side instead of the bed support. Any suggestions?





The top photo I needed to cut a bit more to the left not the right. The reason its a big deal is because the bed has a 90 degree bend and there is a piece of metal that bolts up to the bed support. Of course I've cut into the 90 degree bend and still haven't separated the support from the bed side.

[LILRED66]

Removing the rear cross sill on a fleetside does require removing the four bolts (two on either side), as well as, cutting the welds. I have done it a few times and used a die grinder with a zip wheel (cutting wheel) to do it. Try to score the weld, instead of cutting all the way through the panel/cross sill. By doing so, you can remove the rear cross sill, since the weld is not as strong. After the rear cross sill is removed you can clean up the remaining weld on the bed side and rear cross sill...and not have to worry about welding a kerf in the panel.

Since the rear cross sill is a part of the bed sub-assembly, it is painted the body color...the other cross sills are painted chassis black from the factory.

[kizer]

Yeah I've got most of them painted Chasis black and I was trying to get the last off because it needs attention. There is some small rust and well I wanted to either see if I can fix it.

[kizer]

I'm just wondering if I can get a die grinder with a cut off wheel and squeeze it in on the left so I can re-weld that bend on the right so I have something to bolt to later. I could just grab a welder and weld it backup up and call it quits, but I really wanted to remove it and patch some holes that don't seem easy to get to and hit it with POR15 on the bottom and prime it up for paint later.

[jonzcustomshop]

I have used a pair of vise grips and a broken hacksaw blade to get one off at the wrecking yard.
I just scored it and cut a little, then I spent a few minutes working at it with a hammer and a good chisel.
the weld finally got weak enough that I could wiggle it loose.

[protrash64]

I replaced one bedside on my truck and never re-welded it together. It hasnt moved so I think bolts will hold it well enough going back together.

[kizer]

The problem I'm facing is I cut into the weld and I cut into the bed side that folds along the backside.

So now it appears I have to cut to the left to seperate the pieces. I just don't know if I have enough material in the sheet metal to do so.

After I do seperate I have to then reweld the gap back closed because what I did cut is part of the bed side. I'm just bummed because I didn't catch the potential problem before I started.

Yeah I know its not really anything to you master fabricators, but hey I'm new at all this and my skills are rather limited as well as my tools.

[SCOTI]

Originally Posted by kizer

Yeah I know its not really anything to you master fabricators, but hey I'm new at all this and my skills are rather limited as well as my tools.

Enthusiasm, determination, research, & some trial & error are how beginners become master fabricators (or @ least better fabricators).

You'll need to cut the 'correct' part that's still connecting the 2 pieces. Once they're apart, weld up the 'mistake'. If you don't have a welder, toss the bedside into another truck & any local board member or bodyshop in your area would most likely weld it for you FOC (I know I would).

[kizer]

Haha, nah I will for sure keep it. Just a little annoyed. I'm sure its a common mistake and like you said leason learned.

[protrash64]

I didnt understand what I was lookin at earlier; even though Ive done this. That big square post STAYS on the bedside!!!!! Your bolts are down below.

[protrash64]

OK kizer....got some pics for you. The passenger side Im pointing at is the only cut; as I remember. The driver side is the one that I replaced. Hope this helps out a bit.

[kizer]

protrash,

Yeah I cut there and there is one down below as well that runs up and down. You have to cut it in order to separate the support from the bed side. At least that's what my assembly manual shows. I guess its supposed to be a 2-inch weld.

I probably would of been fine if I had of cut on the left just a tad because where that hole is that I made I separated the post of the bed from the 90degree bend that the bed support bolts to. I grab a photo or 2 when I go back outside. Its like 31 degrees right now and well its just cold hahaha.

[protrash64]

Its been about 5 years since I cut that so I didnt remember. Its about 75* here in Phoenix so Im wearing my thermal shorts today.

[jonzcustomshop]

You just need to grind the factoy weld bead down, when it comes apart there will be a slit where you missed with your previous cut, that will have to be welded up.
A four inch grinder / or cutoff wheel should reach in there.
sometimes I have to remove the safety guard off the tool to get in there for the right angle. Just be sure to yse some thick leather gloves incase the machine starts to get away from you.

[kizer]

Yeah, I'm going to get a short hacksaw blade and try and cut from below to try and minimize my damage/additional fix.

Its a good leason learned and I'm glad you guys aren't hacking on me for a rookie mistake. Then again I'm sure not everybody feels compelled to taking the bed completely apart just to make sure every square inch is undercoated. I'm kinda OCD like that. It would drive me bonkers forever if I don't finish what I started.

I'll snap some photos on the drivers side when I do it as a this is how your supposed to do it.

Oh up above I made a comment about not being a master fabricator. I wasn't implying everybody here is or isn't I was just frustrated and sorta venting and I hope nobody took it literally or as an insult because it was not meant to be. There are so many awesome rigs here and it is obvious that many have spent many hours researching and putting out tons of elbow grease to get them where they are. I'm sure there was a fair bit of money involved as well.

[protrash64]

I bet everybody on here has done something they wish they hadnt!! I just look at it as metal and it can be put back together. You'll get it straight.

[LILRED66]

kizer:

You are going about it properly. The best way learn is to attempt, so you learned by doing one side and certainly will have better success on the other side.

Good luck with your project and keep us posted on your progress.