Mr. Moderator can you please move this whole thread over to Offroad EX Projects under Ricks Bronco 1 and 1/2 this thing has turned into an ongoing thing,no use tieing up this space.
Drilled 1/4" hole thru rivet then took one of the best tools ever..the Uni-bit, just drilled untill the rivet head came off.
Pried tower away and found two rusted holes thru frame. You can see a spark plug thats been in their for years. Look at pic 21 and you can see the tip of it. I wonder if this started the rust? Other side is fine.
Called my buddy Jack who builds and restores old vintage tin cars and makes some nice hot rods and knows how to restore frames. He told me just what I thought...cut the rusted area out and radius the corners. Cracks love to start at sharp spots/edges.
This is a template for the 3/16" plate that's going over the bad stuff. This is where Jack told me something that I did not know. Try to never weld across the frame at right angles but with the frame along the horizontal. That's why the diamond shape. Small right angles are fine but not all the way across. You have a higher potential for cracks if all the way across.
410 again thanks, before I read your post, I called Anderson race cars and off the top of their head they thought 350 to 400#. I would love to do all the things you mentioned. But just don't have the funds for all that right now. I don't have a suspension lift just a 3 inch body lift. For right now if I go with the coilovers and extended radius arms hopefully that will be better then what I have now. That 4 inch extension, I wonder if that is legal with the tires sticking out? How does that effect the rear which is stock 94 Ex 8,8 width?