2015.01.12 - UPDATE! - LET'S TAKE IT OUT BACK...!!!
The new materials finally came in at the end of last week, so this weekend it was important to use my prototype framerail as a template for the driver's side while it was still waiting to be welded / fishplated to the original frame on the truck.
Transferred all the cut lines from the first framerail to the new one....
Then made my wedge-slices to allow me to get all the angles I needed to match the new frame profile....
Tacked it all into place so that it could be compared to the original and tweaked as needed....
Here they are clamped together as a "mirror pair"...
The decision was made last week to simply run the new framerail all the way out the back of the truck instead of trying to scab it together with a small 12" - 18" section of the original frame..... it just didn't make sense and ultimately was more work than just using a clean section of 2" x 4" tubing all the way throughout.
In this image, you can see the extended length of the new framerail sections (left side of photo) to allow them to pass all the way out the back of the truck. Keep in mind, the framerails are upside down in this photo so don't let their orientation confuse you.
And a shot of a partially finish-welded and flap-wheel dressed part waiting for a final test fit....
..... and a parting shot of the night with the frame in position!
So the next step will be to cut out the fish plate shims and drill all the through holes that are needed to weld them in place. I'll built two sets just to keep the efficiency as high as possible, so I'm not sure if I will have enough time to cut and metal-finish them tonight AND get them welded in.... we'll have to wait and see on that one.
-G