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Independent Front Suspension Installation - Volare, NOOOO!

Frontend Installation Carbide Tip
A Carbide tip on the die grinder... 
   
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Frontend Installation Carbide Tip
A Carbide tip on the die grinder enabled him to open up the holes in the old framerails for the Rosetta welds.
Frontend Installation Plumb Bob
Notice that the plumb bobs... 
   
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Frontend Installation Plumb Bob
Notice that the plumb bobs on the new framerails match the reference points marked on the floor from hanging them on the old framerails.
Frontend Installation Stock Boxing Plates
Stock boxing plates serve... 
   
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Frontend Installation Stock Boxing Plates
Stock boxing plates serve as a welding splice or splint between the old 'rails and the new.
Frontend Installation Boxing Plates
The boxing plates were welded... 
   
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Frontend Installation Boxing Plates
The boxing plates were welded inside the existing frame ends.
Frontend Installation Frame Measurment
Before welding the new 'rails... 
   
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Frontend Installation Frame Measurment
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.
Frontend Installation Reinforcemnt Bar
After tack welding the new... 
   
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Frontend Installation Reinforcemnt Bar
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.
Frontend Installation Crossmember
To step the TCI front crossmember... 
   
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Frontend Installation Crossmember
To step the TCI front crossmember 1 inch, KA Custom drew the cut line on the crossmember ends.
Frontend Installation Plasma Cutter
Kevin and the plasma cutter... 
   
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Frontend Installation Plasma Cutter
Kevin and the plasma cutter made quick work of the 1-inch step on both sides...
Frontend Installation Crossmember
...after which he cut fill... 
   
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Frontend Installation Crossmember
...after which he cut fill pieces.
Frontend Installation Stepped Crossmember
Using the die grinder, he... 
   
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Frontend Installation Stepped Crossmember
Using the die grinder, he smoothed the step fill pieces...
Frontend Installation Stepped Crossmember
...and the stepped crossmember... 
   
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Frontend Installation Stepped Crossmember
...and the stepped crossmember ends.
Frontend Installation Fill Pieces
After welding in the fill... 
   
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Frontend Installation Fill Pieces
After welding in the fill pieces and allowing the crossmember ends to cool...
Frontend Installation Centerpoint Measurment
...he flipped the crossmember... 
   
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Frontend Installation Centerpoint Measurment
...he flipped the crossmember right side up and measured each end to determine and mark its center point.
Frontend Installation Tack Welding
Once KA Custom determined... 
   
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Frontend Installation Tack Welding
Once KA Custom determined the correct placement of the front crossmember and assured the crossmember was level, it was tack welded to both framerails.
Frontend Installation Diagonal Ramp
Since the original framerails... 
   
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Frontend Installation Diagonal Ramp
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.
Frontend Installation Tack Welding
Tack welding and finish welding... 
   
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Frontend Installation Tack Welding
Tack welding and finish welding the new front subframe...
Frontend Installation Finish Welding
...to the existing frame-rails... 
   
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Frontend Installation Finish Welding
...to the existing frame-rails came next.
Frontend Installation Crossmember Bead Weld
With the frame in one pie... 
   
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Frontend Installation Crossmember Bead Weld
With the frame in one piece...
Frontend Installation Bead Weld
...KA Custom completed the... 
   
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Frontend Installation Bead Weld
...KA Custom completed the front crossmember's bead welds.
Frontend Installation Cardboard Template
By using a cardboard template,... 
   
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Frontend Installation 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...
Frontend Installation Boxing Plates
...After cutting the boxing... 
   
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Frontend Installation Boxing Plates
...After cutting the boxing plates out of sheetmetal, they were tack and bead welded to their new home.

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