I'm planning on lengthening my Early Bronco 10". I have 2 frames in good condition so my plan is to use the front part of one with the rear part of the other. Cutting the rear part 10" longer and splicing it to the front. I'm planning to cut it at the raised section over the axle just in front of the cross member. I figure this will put less stress on the joint than cutting in the middle of the frame.

What is the best way to join them together? Sleeve them? plates over the joit? both? How can I make sure they stay straight? Should I make the frame cuts at an angle to give more weld surface? Any tips would be appreciated.

TIA

do what you want obviously, but whay do you want to lengthen the bronco?

I want it longer for more room inside for the family. More driveline length for a double transfer case. A longer wheel base for the rocks.

By stretching the body 10" I can get a 3rd row of seats so 3 kids and my wife can all ride.

i would cut it about 12-15" from the rear crossmember, slide a piece of box tubing over it that is roughly 3/16 to 1/4 wall, and relatively snugly fits over the frame rail. there should be 8" of the crossmember end of the frame inside this sleeve. then, slide this sleeve and welded on rear crossmember so that 8" of the forward section of the frame is inside the sleeve. with the 10" stretch that you want, this means that this sleeve should be about 26" long.

this method will be way strong and a lot easier than if you tried to splice in a section of frame. making really strong butt welds is a PITA and i dont want to have to worry if my welds were strong enough or not, especially on my frame! :eek: :D

good luck, and remember to post PICS!!! :flipoff2:

oh yeah, forgot. also, for extra strength, drill some 1/4" diameter holes in the sleeve and then plug weld it to the frame where it goes over it for extra strength.

Originally posted by 9V
i would cut it about 12-15" from the rear crossmember, slide a piece of box tubing over it that is roughly 3/16 to 1/4 wall, and relatively snugly fits over the frame rail. there should be 8" of the crossmember end of the frame inside this sleeve. then, slide this sleeve and welded on rear crossmember so that 8" of the forward section of the frame is inside the sleeve. with the 10" stretch that you want, this means that this sleeve should be about 26" long.

this method will be way strong and a lot easier than if you tried to splice in a section of frame. making really strong butt welds is a PITA and i dont want to have to worry if my welds were strong enough or not, especially on my frame! :eek: :D

good luck, and remember to post PICS!!! :flipoff2:

I woudnt sleeve it with tubing cause then you couldnt actually weld the frame. I would cut a cut like this \\ (only more exagerated) and weld. Then I would plate it with some 1/4 on all 4 sides. I did a frame extension and finding sleeving that is a perfect fit on a frame is a PITA.

Plus, this way you would have a butt weld reinforced by plating. With just a sleeve you might get some V action going of the frame inside the sleeve.

I had a frame welded once (before I got a welder and was burning metal) by a profesional welder. He worked as 1 of the 2 profesional welders at a shop that specializes in frame straightening and major body work. This is how he did my frame that was broke.