Frame Crossmember Repalcement

[78clubcab]

I want to replace the frame crossmember just forward of the rear axle because mine is rusted and pitted and have found a suitable replacement from a 5/4 ton army parts truck. The cross members are riveted from the factory. I was thinking a grinder with a cutting wheel would be the best way to remove them. As for re-attachment, grade 8 bolts. I hate to do this but alot of the same cross members [in front of the rear axle] I've seen on trucks from my area are rusted badly, but for some reason this seems to be the only cross member to rust like this. Am I making a mistake in thinking of replacing it because I'll be cutting factory rivets to do so? Is a moderately rusted but riveted k-member stronger than a rust free but bolted k-member?

[QuantumJo]

When I removed cross members from my 79 W300 I used an Oxy-acetylene torch. I got the rivet head red hot and hammered it off with a chisel. It was suggested to me to use huck bolts in replacement of the rivets.

[DODGEBOYS]

quick and easy with no torch mess is cut an X in the head of the rivet with a cut-off wheel and then air chisel the heads off

[Gordon Maney]

When I removed cross members from my 79 W300 I used an Oxy-acetylene torch. I got the rivet head red hot and hammered it off with a chisel. It was suggested to me to use huck bolts in replacement of the rivets.

What is a huck bolt?

[Gordon Maney]

quick and easy with no torch mess is cut an X in the head of the rivet with a cut-off wheel and then air chisel the heads off

Neat idea!

[QuantumJo]

What is a huck bolt?

https://alcoa.com/fastening_systems/...ck/en/C50L.pdf

[Gordon Maney]

https://alcoa.com/fastening_systems/...ck/en/C50L.pdf

You have to have their installation tool?

[QuantumJo]

Im not sure... I have yet to use the system.

[Don Williams]

If memory serves me correctly.... Rivets are an odd size compared with bolts. You will need to drill the holes to the next larger size bolt. I personally would much prefer a solid (no rust) frame member bolted in with grade 8 hardware as opposed to a rusted one riveted in.

[78clubcab]

I was at the military junkyard again yesterday, I and think the grade 8 is the way I'm going to go. I picked up a front valance panel [grille extension] because I was shocked to find my was bad on the driver's side. Bad case of tinworms, and I tried to fill in with mig welder, but the metal just blew away and the holes got bigger! MAJOR score on NOS right side inner fender, so I bought it at a great price even though I don't think I'll need it. Paint work is coming along nicely now!