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89 Suburban is gone....added a K5 in it's place..87 V30 WONTON

Here's where I'm at tonight. My body said no mas. When I spot weld / finish weld the bungs in, should the Johnny Joints be threaded in or left out?

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When I do any links, I like to set up with almost all the way threaded in. It’s stronger, and you can always cut more tube off if you need.
 
@Fastereddie I have them threaded in all the way. I'm wondering about welding the bungs to the links with or without the Johnny Joints threaded into the bungs?
 
Top or bottom when welding?

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Tonight's progress pics. Cut and cleaned off the axle. I was wanting to tack everything by the end of the weekend, but cleaning the axle took a lot longer than expected. So here we are. As long as something is done each night the schedule should be okay.

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Axle tacked up. Going to pull the crossmember and start fitting rear link mounts. Need to modify the crossmember and trim the body mounts for clearance. @Fastereddie came by yesterday to help point me in the right direction.

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Pulled and cleaned the crossmember. Cut / bent new ends for clearing the link mounts out of 1/4”. Hopefully spreads the load out a little better too. Bent the crossmember last year at BB.

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I like the idea of spreading out the mounting surface at the frame. I had a buddy that cracked his frame at the crossmember and I felt it was because it needed a wider/longer mounting flange.
 
Last year I caught it on a rock and it tweaked the frame along with the crossmember. Hopefully this will help that along with a skid plate mounted on it.
 
I will tell you that I saw a frame rail flange get bent by the crossmember/skidplate mount being on just the flange. There isn't really enough strength in the flange for it alone to support a decent impact on a rock. If the vertical portion shares the load, it should be much better. This is my idea from being around semi trucks for years. The flanges on those frames never do all of the work if supporting the weight, it is shared with the vertical steel.
Just something to consider if you are planning for upgrades, at least in my opinion.
Nice parts and progress by the way!
 
Thanks. I'm hoping once I get it tacked in I can add a support to the back of the tcase and tie it into the frame again then put a 1/4" skid to cover it. Kinda double up the crossmembers there. Just winging it till tonight when I cut this one and see where everything lands. My old 2wd prerunner had a tube setup with flange mounts to the frame and a suspension bushing for the trans. That's the idea on the back if possible.
 
Hit a snag with the wider crossmember mounts, they fit but when tacked up the assembly is too big to wedge in the frame and fit the trans mount. No room to get both sides on top of the frame flange. I'll be modifying the mounts to bolt up to the crossmember after the new pieces are on the frame, basically a modular mount setup. Any thoughts if this is a bad idea?
 

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