Mikes Ford Bronco Frame REPLACEMENT section.

So a co-worker and friend of mine picked up a Ford Bronco several years ago. He first had a 66 Mustang that he realized wasn't what he really wanted to build and so he refocused and settled on an early Bronco.
He had a fairly rusty project to start with and first began by redesigning the floor patches, had them laser cut, and powder coated with zinc to seal them for the coming stent of time that is inevitable for most of us with projects such as this..............YEARS............   :-)

One other area that needed serious attention was the rear half of the frame rails. Basically everything after the  front set of leaf spring mounts was a prime candidate for repair. Rather than patch in repair sections, he opted to redesign the entire rear rail, however wanting to keep it original looking was key.

After some playing around and discussion, it was decided to make side plates that matched the original contours, and make two shallow "C" channel caps for the top and bottom. We cut slices where the channel need to follow the contour of the side plates and the pictures below show the assembly and welding process.

                                                           Bead after bead, nice and clean!

Here you can see the slices that were made in the channel in order to follow the contour of the side plates.

More weld shots.

Here I attached the Shock strut. This was of course set up based on the original placement.

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