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Made up these tools to mark and cut the 2x2 tube Ill be running for frame tie ins. Just used some scrap angle and strap. Clamped them in position then welded them. Heres how they sit on the Jeep. Im going to run 4 supports. The front 2 and rear 2 are a little different angles because of the frame shape. Simply set it on the tubing, mark it... Connect the two sides... And your ready to cut! 4 frame tie ins 👍
Start at the rear mount. Hold the tie in against the spring mount bracket, then mark the floor. Clean off the spring bracket so ya dont forget to do it later. Ill be welding the tiein to this bracket to strengthen it to 👍 First cut. Dont go crazy on length of cut, yet. This is what it looks like inside. Look at all that seam sealer 😮 Its easier to clean off now before ya start bending stuff up. Now cut across the first two cuts. Start bending up the floor... Try the tie in, cut and fold some more till it fits. Like this. Ran outta steam tonight! These flaps will get welded to the tie ins later.
Got the first tie in tacked on. Measured from the rear tie in 48 , the length of my plate for the boat side, forward to locate the forward tie in. Marked and cut like the rear but ran square into the factory knock out hole in the floor! Glued in with seam sealer 🙄. Have to figure that out when I seal up the floor.
So since Im going with 4 support tie ins, the middle two will be spaced 16 apart. Make sure to center the front and rear ones at 48 so you have room to weld ends on.
Scraping and cleaning the seam sealer is a pain! I found a trick to save a little time. Clean it off above this seam area. Then make your connecting cut. The piece of the seam thats bent out will the be only held on with one spot weld. Pry that piece off and I just leave primer to clean off! Cleans up a bit easier 👍
I added these 1x1 supports for 2 reasons. Itll help support the plate in this vulnerable area and itll keep the tie ins in proper position while being welded. I used small chunks of 1x1 to fill in and support in this area. Then lotsa welding 😋 All welded up 👍
On the outboard side of the plate I beveled the edge so it would fit better. Grind the welds smooth where the plate lies. Then position the plate where you want it. My plate is 48 x 15, 3/16 thick. I left about a 1/4 overhang on the inboard side. There is a angled area on the frame that this will contact to make welding easier and provide better support. Made some index marks after I drilled and installed clecos to hold it in position when I install it on the Jeep. I also marked the other side of the plate to drill 1 holes thatll line up with the middle supports to plug weld them.
Next is the plate for the boat side piece.
This is what the floor board area looks like. Cut the tabs to a comfortable length, then hammer them down to the 2x2 tie in. See the gap on the left... I cut and bent some heavy gauge sheet metal to fill the gap. Then weld it together. I struggle with sheet metal welding so it kinda looks like crap 💩. Gonna use seam sealer to fill the gaps.
Finished welding up the floor, then used seam sealer to fill in the gaps and smooth it out. Got the top welded. Then flattened out the welds and used a little bondo to smooth it out. Im not a body man so I literally used a 60grit flappy to smooth it out 😂. Its Gonna get bedlined and hopefully the sill plates will fit up when Im done 🤞
