Frame Reinforcement

[byates2]

I had to cut some of the frame to fit the headers i chose to put on the engine. I also had to cut a hole in the crossmember to fit em. I'm wondering how i can reinforce the frame without having to weld. I want to get some strips of heavy duty stainless and bolt them with grade 8 bolts. I want to get strips and bolt them above and below the hole in the crossmember and one on the frame where to deepest cut is..... any other ideas. i want to stay away from welding because i dont have the means or a way to do it. I'm hoping its possible to do without having to weld

[plumber36757]

Would have been easier to buy a set of headers that work. That's a mess under there for sure. Good luck sounds like you have a plan.
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[byates2]

i searched and searched and supposedly these headers were supposed to fit without major modifaction.... now i wonder what major modifaction actually means

[Stocker]

I'd bite the bullet and pay someone to properly repair both the frame and the crossmember, and that means welding. Not to give you a hard time but I wouldn't have cut structural pieces if I couldn't weld... just my 2 cents.

[71 super]

Did you move the engine stands to the v8 position? It looks like your problems may be because headers are hitting due to engine being in 6 cylinder position. If headers are correct for truck the cutting you have done should not have been needed.
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[68 TT]

Originally Posted by byates2

i searched and searched and supposedly these headers were supposed to fit without major modifaction.... now i wonder what major modifaction actually means

Maybe they sent you the wrong headers. I have had at least five different brands of headers designed for small block 67-72 trucks and they all cleared with ease in both the forward and rear engine mount locations. Even the ones designed for Chevelles clear the truck frame completely. Those mods to the frame should not have been required.

What application are those headers for?

[treveiger]

Interested. Keep us updated.
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[Artikgrau325is]

Yikes, I hope those headers are absolutely badass. If you get the strips of stainless steel to reinforce the cuts in the frame, won't they cover up the notches you made for the headers and (thus) render your modifications null?

You may not have the means to do it now, but welding may be a useful skill to learn when building and restoring old vehicles. I too have no real clue about welding, but as soon as I struck my first arc I was hooked. Not trying to be pushy against your situation, everyone has their own circumstances that limit what can be done (money or time usually being the biggest culprits), but down the line it may be something to consider.

Main piece of advice I have to offer:

It's easier to find out why something doesn't fit, than to make permanent modifications to make it work.

[treveiger]

I love welding but can't do it worth crap lol. There not pretty but there solid
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[Tinkermc]

If your welding looks bad then practice would help. But in the meantime just pay a pro to fix the mess.After all it's only money.

[BurnoutNova]

I don't think it looks that bad. Personally, I would leave it the way it is.

[gale]

Originally Posted by treveiger

I love welding but can't do it worth crap lol. There not pretty but there solid

They may not be as solid as you'd like to believe. I have just about 60 years' experience in all methods of welding and I do not trust anyone's welding if it doesn't look good, or at least very neat.

[gale]

Originally Posted by byates2

I had to cut some of the frame to fit the headers i chose to put on the engine. I also had to cut a hole in the crossmember to fit em. I'm wondering how i can reinforce the frame without having to weld. I want to get some strips of heavy duty stainless and bolt them with grade 8 bolts. I want to get strips and bolt them above and below the hole in the crossmember and one on the frame where to deepest cut is..... any other ideas. i want to stay away from welding because i dont have the means or a way to do it. I'm hoping its possible to do without having to weld

Most of the responses have been pretty nice but there is an underlying theme in that the cutting more than likely wasn't necessary. I've worked with metal almost my entire life and I can't tell what sort of tool you used to cut the frame.

Your idea of bolting on strips of stainless has no engineering merit at all. You will wind up with a perforated frame you can throw away.

[mmiddle]

Originally Posted by gale

Most of the responses have been pretty nice but there is an underlying theme in that the cutting more than likely wasn't necessary. I've worked with metal almost my entire life and I can't tell what sort of tool you used to cut the frame.

Your idea of bolting on strips of stainless has no engineering merit at all. You will wind up with a perforated frame you can throw away.

2X on that! Drilling and bolting is just going to further weaken the structure at a critical area. To do this right you need to clean up those cut-outs and properly weld in plate.

As an R&D guy for more than 20 years.... Rough edges are a sure-fire place for cracks to form.
It may or may not ever be a problem, but if you head-on the truck that engine is likely to visit you inside the cab.

[gale]

Another consideration is what will the next owner think of your work. I've redone quite a few trucks and motorcycles, not even one with the thought of selling it. But invariably someone sees it, likes it, and makes me an offer I can't walk away from, because I know I can do this again and probably better.

I didn't even think about ragged edges being stress points, but then I've never left a ragged edge.

[mmiddle]

To be honest, I it were my truck or one I just bought. I would pull the motor, cleanly dress the cuts and weld in 3/16 plate. And when I sat weld, I don't mean with a flux-core wire welder. These need at the very lest solid core MIG wire or best Tig welded. You have created very critical stress points.

I know it may sound like we are being harsh here. Don't take us wrong cutting or notching the frame and cross members is not a big deal, many of us do it for one reason or another. But, What has us freaked out is the roughness of the cuts and the idea of bolting patch plates around the holes.

I know this is apples to oranges... but aircraft have fallen out of the sky due to small scratches in a wing spar. Even tooling marks in a machines surface can create a stress point.

[sKnNyPpY]

I might get scolded for this, but I personally would not drive or ride in a vehicle with a frame that looked like that. Please get it fixed, no set of headers are worth the mess that could get you in.