Rusted out crossmember replacement

mattoney · #1 (**permalink**) 01-19-2008, 12:46 AM

I have two Bronco IIs both with the same problem. Apparently our wonderful Indiana weather likes to get after these things, and one problem I'm seeing on both of them is in the very rear of the vehicle. Some sort of "body crossmember" that is built into the floor where the last body mounts attach likes to rust out. This doesn't appear to be a crossmember like on the frame where the transmission would attach to. It seems to be part of the body. It's painted the same color, and you can see the top of it with the door open and the carpet removed. When this thing rusts out, the whole body falls down on the frame, and usually damages the back door because the alignments all out of whack or it starts hitting the bumper, or both.

I have checked various places and I've not seen a replacement for this anywhere, so I'm turning to you guys. I'm guessing some sort of homebrew remedy is going to be required here. Does anybody know a fix for this? Has anybody attempted it before?

Yea, I know it's probably going to be more work than its worth, but what else am I gonna do this winter? Get a job?!

I appreciate any advice you guys can give....or experience....or money! Have a good one!

jdhv002 · #2 (**permalink**) 01-19-2008, 09:40 AM

i'm sure it would take some time but if you had a welder and a cutting torch you could fabricate something put under there and bolt to the body. Or you could come get this 86 body out of my yard before my wife sells it for scrap.

mattoney · #3 (**permalink**) 01-19-2008, 10:41 AM

Welp I do have access to a mig welder and an arc welder. Cutting tool wise, I don't have a torch but I've had a sawzaw I've been good friends with for years.

As for the body, that would depend very much on its condition, and more importantly your location

.

jdhv002 · #4 (**permalink**) 01-19-2008, 11:07 AM

I'm in AR,. Thats the only solution i can thing of. If its a crossmember and not acually a part of the body, maybe you could find one at a junk yard and cut it off. But i would assume in your area they would all look the same, rusted out. Besides if you bult one it would'nt have to look preaty just serve the purpose.

rebocardo · #5 (**permalink**) 01-19-2008, 11:17 AM

I looked this up in a crash book, so the numbers might be dated.

member, floor cross e4tz 98102a24a $47.07

I would suggest a trip to the dealer to see if one can still be located.

McQue · #6 (**permalink**) 01-19-2008, 09:46 PM

I just went through this this past fall...
I fabricated everything from metal I got out of a metal waste yard
Had to cut out all bad metal then fabricate and weld in a new rear sill, the reinforcement, with lip for the hatch rubber seal, and then fabricate ears to weld to sill and tie them into body. Held up body at correct height with jacks while welding the ears into the inside of body by tailight buckets. That ties eerything together structurally. The floor does not hold the body up. The rear sill hold the body up when it is tied in/welded right. the sill sits on the body mounts. Then I replaced flooring last.
You may find rust damage on upper part of bracket that leaf springs bolt to. And if you check your other body mounts, they may need attention to.
I'm glad I did it...the Bronco rides ery nice now, with a suspension that works the way it is supposed to.

Visit this site ...you may get a better idea of what I am talking about...

http://www.directfordparts.com/partl...=2&catalogid=2

McQue

mattoney · #7 (**permalink**) 01-19-2008, 09:56 PM

Wow. That's cool as heck you guys got all this stuff. I've been checking LMC Truck and JC Whitney, and there's stuff like this out there just waitin for me. I wish I could find stuff as good as you guys.

Well I'm gonna have to tear into these things and find out what I need. I figured I was just gonna build something out of angle iron or somethign to hold the body up, but here's the factory panels. Probably cheaper to do it my way, but I bet it'd look better and function more adaquately.

Thanks for the help!

rebocardo · #8 (**permalink**) 01-21-2008, 04:15 AM

I would stick with the factory stuff for everything other then the floor pan. If you wanted to use a sheet of 12/14/16 gauge for the floor pan I think that would be okay. While you are at it, I would put in an access door for the fuel pump.

mattoney · #9 (**permalink**) 01-21-2008, 11:13 AM

The floorpan itself for my 87 is in good shape. no rust, surprisingly. but the one for the 90 is rusted about 3 or 4 inches back from the sill. still, beyond that its in great shape. just that one little area. i'll see what i can do about getting started on it soon.

thanks for all the help everyone. I appreciate it.