Tonight, I finished the front frame rail where the core support bolts. I also removed the front crossmember and spring cups. It was a major undertaking. I went through countless sawzall blades and a couple grinding wheels. The rivets are very difficult to remove. I found more rust in the frame rail. I expected it on the driver's side because I could see it in the spring cup, but the passenger's side was a surprise. It will be easy to fix though.
This patch is from the frame rail of another '66 F100 I parted out years ago, so it's Genuine Claycomo Ford steel in it.My welder was in a good mood.
I cut off the flange and ground it flush for welding.
Very nice finish:
The main suspension crossmember and engine cradle is a bear to remove. I started by cutting it out with a sawzall:
Driver's side looking out from inside where the crossmember was. It was arc welded in at the factory and they did a decent job. Removing the last sections on each side was tough. I haven't ground off the old welds yet.The spring cup was riveted in and the rivets are a huge pain to remove.
My next rust repair:
Passenger's side with the crossmember removed but the spring cup is still in place:
Spring cup removed:
Both front rails when I went in for dinner. I'm almost done working this frame.
Next, I'll remove the boxing steel where the old steering box was because I'll do my own boxing to support the new crossmember.