Front Frame Rail Tip Replacement: Notes

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1 - FONT END SHEET METAL (FESM) BRACKET

2 - CROSS-FRAME TUBE

3 - FESM BRACKET

4 - LEFT FRAME RAIL

5 - COMPATIBILITY BEAM

6 - BUMPER MOUNTING BRACKETS

7 - RIGHT FRAME RAIL

Mount the vehicle on appropriate frame correction equipment ("frame rack") and using a three-dimensional measuring system measure frame/body and correct to vehicle specifications.
Release welds holding compatibility beam (5) brackets to rails (4 and 7) and remove - if compatibility beam is to be replaced also, the brackets only need to be removed from the undamaged rail.

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At the centerline of the cross-frame tube, use a reciprocating saw to make a vertical cut (3) through the frame rail to the tube (2) from both the top and bottom.
Using either a reciprocating saw or a plasma cutter, cut forward of the tube (4) to release the rail (1) from the tube (2).
Grind off any remaining rail or weld attached to the tubular crossmember forward of the original vertical cuts in preparation for the replacement part.
Any cuts into the tubular crossmember should be welded and dressed smooth before proceeding.

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From the removed rail, cut weld-backers (1) which will fit snugly into the original frame at the cut location. Position these backers so 12.7 mm (1/2 inch) protrudes from the section location.
Cut the service part vertically at the same location as the original frame.
Clean and de-burr all cut edges, remove e-coat within 25.4 mm (1 inch) of the joint from the inside and outside of all the surfaces.
Make sure that a slight bevel is created at the butt-weld joint to allow complete weld penetration.
Refer to the weld chart for proper weld rod and approximate welder settings, and adjust the welder to create a proper weld bead. Refer to FRAME, TECHNICAL SPECIFICATIONS .

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Position new (cut) rail tip (2) in proper position and tack-weld in place (1).
Weld replacement tip in place using a skip-stitch process - welding in 50.8 mm (2 inch) increments, weld the rail on opposing sides to avoid distortion, Also allow the rail to cool between the welding operations.

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Position and tack-weld FESM bracket (2), bumper mounting bracket (1), and compatibility beam (3).
When dimensional accuracy is confirmed, finish weld all components using the original weld locations as a guideline.
If the FESM brackets and bumper mounting brackets were not pierced, create the appropriate piercings at this time.

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Cosmetically dress welds without removing any base metal - a skim coat of filler may be utilized for an improved cosmetic appearance.
Refinish all components to a production appearance.
On all areas (1) inaccessible to the refinish operation, apply a creeping type rust proofing material ensuring 100% coverage. Be especially focused on those areas where welding may have burned off the original corrosion protection.