Paint and Body Frame rail dimensions

[KRUISR]

Slightly larger gap on passenger side vs driver side.

Here you can see the frame rails bow back toward the middle as the rails approach the rad support.


I included these just as a reference. This is a 50k mile car. I did replace the driver side frame rail from firewall to about 4-6" behind the rad support. Passenger side rail is OEM. Lower rad support is original as well. Where rad support connects to upper aprons, OEM - untouched.


A couple more reference pics.

 

[keel]

Thanks for showing that, it looks very similar to what I have set up and that is reassuring.

Did you have to make any modifications to the core support or the frame rails to get the core support to fit tighter against the vertical flanges on the frame rail? You can see in the pictures I posted that there is a small space there.

I was thinking I could maybe try shaving a little material off the front or I could stack some sheet metal on to the flange to fill that gap. Or maybe bend them forward. Not really sure what would be the best choice.

 

[KRUISR]

My connections between frame rail and core support are OEM - I have not modified or repaired them. Where you are seeing the gap, have you tried "persuading" the core support further into the rail? Is there any flange or tab on the bottom of the rail at that joint that is preventing the core support from going back all the way.

When I repaired the driver side frame rail (replaced most of the rail), I made may splice a couple inches back from the frame rail/core support connection. So my connection is still OEM.


I made my frame rail splice in this area. If you look closely you can see the reinforcing place I welded on the inside of the rail. I also welded one on the bottom and outside, overlapping my butt weld connection.

 

[keel]

I tapped the bumper supports with a mallet to get the core support to seat as far down as I could. It won't budge any further.

It is contacting the inner fender aprons at the bottom before it seats all the way.

 

[KRUISR]

Just ran out to the shop and took a couple more pics - hope they help.


Passenger side



Driver side

 

[keel]

Thanks, that should help me dial in mine. Anyone have any suggestions as far as the best way to get my core support to seat properly?