Front Frame Rail – Driver’s Side, Radiator Support w/ Brace, Inner Panels

The radiator support top rail was in good shape that has the stamped number and was retained to weld onto the new panel. The new panel is a bit wider and has some holes that are a little different, but will work fine.

The rust was bad on the top of the rail, and I cut it open to see how bad it was. It was rusted around the nuts for the K-member and needed to be replaced. I go around and make things before they are cut loose to have a reference for latter alignment.

The inner panels were half cut loose before I started and came off fairly easy. I dropped the K-member with all the suspension still installed.

I cut and drilled the spot welds for the front rail and removed the lower radiator support with the rail. The torsion brace had rust on the bottom where the frame rail mated, and needed to have a patch made to replace the bad metal. I also noticed the lower corner of the A-pillar on the driver side needs some attention as well.

The car was set up on level with multiple levels, and a laser level to get things lined up. I mock everything up with tack welds and clamps to be able to move things as needed.

The new frame rails come bare and the brackets have to be removed from your factory rail and welded to the new. At this point we were still thinking about running a four-speed, and the bracket was positioned back where it was on the original.

I like to clean up things with cleaning and wire wheels before painting interior surfaces that will be cover with a repair. Once everything was in alignment, I went around and started welding it to make things solid.

I tend to check level and laser quite frequently to make sure nothing has moved. The sooner you catch any issue, the easier it will be to fix at that point then to come back later and address it.

The front end getting aligned to the new rail, and inner panels being marked for location. I fit parts, drill plug weld holes in the panels (or punch if I can), and weld after final fit.

The front support was shaped a bit off from what was needed, and I had to cut the edges apart, fit to the panel, and re-weld. After the frame rail, I worked on matching up the radiator support, and then did the side panels.

Once the radiator support was square, the inner panels aligned, the shock pocket was fit and marked. I welded the pocket to the rail and assembled the front end with new fenders.

With everything looking good, I marked the weld locations, pulled things apart, and cleaned where the plug weld will be.

I finished up the weld the the mount tabs that mount to the cowl, and across the front edge of the radiator support top rail.

After the top was done, I worked on the shock pocket brace that attaches to the inner panel.

Then I went back to the lower radiator support factory piece and the aftermarket brace. With the brace on top of the original, the grille support bracket needed to be modified.

I cut the ears off, and changed how the bracket attached to keep the correct distance as original.

Once everything was cleaned welded and cleaned up, the front end was fit again.

First with the original hood, and then with a new one that we were waiting on.

It’s starting to look a little more like a car again, but things will change shortly. I have to pull all of this off to continue on with repairs.

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