 A Carbide tip on the die grinder...  A Carbide tip on the die grinder enabled him to open up the holes in the old framerails for the Rosetta welds. |  Notice that the plumb bobs...  Notice that the plumb bobs on the new framerails match the reference points marked on the floor from hanging them on the old framerails. |  Stock boxing plates serve...  Stock boxing plates serve as a welding splice or splint between the old 'rails and the new. |
 The boxing plates were welded...  The boxing plates were welded inside the existing frame ends. |  Before welding the new 'rails...  Before welding the new 'rails to the old, Kevin made some measurements and confirmed the rails were level with the carpenter's level, or in this case, the pro vintage custom truck builder's level. |  After tack welding the new...  After tack welding the new framerails to the existing frame, Rob welded a reinforcement bar on the front and measured the width to fit the crossmember. |
 To step the TCI front crossmember...  To step the TCI front crossmember 1 inch, KA Custom drew the cut line on the crossmember ends. |  Kevin and the plasma cutter...  Kevin and the plasma cutter made quick work of the 1-inch step on both sides... |  ...after which he cut fill...  ...after which he cut fill pieces. |
 Using the die grinder, he...  Using the die grinder, he smoothed the step fill pieces... |  ...and the stepped crossmember...  ...and the stepped crossmember ends. |  After welding in the fill...  After welding in the fill pieces and allowing the crossmember ends to cool... |
 ...he flipped the crossmember...  ...he flipped the crossmember right side up and measured each end to determine and mark its center point. |  Once KA Custom determined...  Once KA Custom determined the correct placement of the front crossmember and assured the crossmember was level, it was tack welded to both framerails. |  Since the original framerails...  Since the original framerails are 6 inches wide, KA Custom used the plasma cutter to cut a diagonal ramp to mate the new 5-inch front framerails to the 6-inch 'rails. |
 Tack welding and finish welding...  Tack welding and finish welding the new front subframe... |  ...to the existing frame-rails...  ...to the existing frame-rails came next. |  With the frame in one pie...  With the frame in one piece... |
 ...KA Custom completed the...  ...KA Custom completed the front crossmember's bead welds. |  By using a cardboard template,...  By using a cardboard template, Kevin determined the boxing plates' correct dimensions for the old framerail sections at the front edge underneath the cab... |  ...After cutting the boxing...  ...After cutting the boxing plates out of sheetmetal, they were tack and bead welded to their new home. |