Well all this is my first post. (I pray I don't have to post a help). Recently I have noticed that there are more posts for mounting filters, and pre screens after the Hutch mod. I am just wanting the FTE brotherhood to know that there are guidelines from the manufacturer about drilling and welding the frame. I will focus on the drilling NOT welding. I am Quoting from a 2004 Ford manual. My other option is a 2001 Manual, not at my current disposal, (at work). I think the information is for the most part is identical, but the 2004 is less wordy.Here goes. "Drilling Precautions. 1. Holes that would weaken the frame sidemember's top or bottom flange. 2. Holes are not to be drilled in the sidemember's top or bottom flange. 3. Holes to mount brackets, out-riggers and supports, may be drilled in the vertical frame side rail web with the following restrictions.
Material between edge of hole and inside of upper or lower flange must not be less than 1.5 inch for low carbon steel (36000 psi yield). .The minimum edge distance between any two hole up to 5/8-inch diameter holes, the minimum edge distance must be 1.5 times the diameter of the largest hole. .No holes will be allowed to exceed 0.75 in diameter. All attaching fasteners, including flat washers, must be of high strength steel, (Grade 8). This is just what I found. Page 2004 manual. 502-02-13. Or 2001 501-02-52 and 53. Of Ford Super duty, and Excursion manual. If anybody has more updated information, please let us know.

 

I always use Grade 8 (it's just me), and really try to never drill a hole in my frame. So far, I haven't had to.

There are plenty of spare holes already in the frame to use, and I've used a bunch of 'em!

Pop

 

Great first post! That is something that I have wondered about. Thank you for the information.

 

How is the 177th post the first?

 

I think he meant "thread"..... Too funny...

 

Ahh.. ten-four.

 

I, too, have never had to drill a hole in the frame. I have always fabricated brackets that took advantage of existing ones. My fifth wheel hitch mounting rails, however, were installed at the RV dealer according to manufacturer specs and were drilled thru the top rails. I never had any issues with them.

 

That is the smartest way to go!

 

Scared to put a hole in a frame huh..... How's this make you feel?

 

It makes me feel like I could never trust that truck again insofar as payload and off-roading go.

Those welds would forever be in the back of my mind every time I was behind the wheel.

There are far stronger ways to cut and weld in extensions and contractions in a frame. Straight cuts would not be my first choice.

Easier? Yes.

Stronger? Not-so-much.

Pop

 

Hmmm... I think that the 4x4 converter may have drilled some holes in my frame to add the front axle and the transfer case cross-member.

Welding on the frame requires disconnecting a whole bunch of electronics first (I posted two Ford TSB's warning about welding on your vehicle recently in that alternator thread...)

But the best thing is that John did all that work removing the body and shortening that frame without even getting his white shirt dirty!


Pop: Scarf joint?

 

Don't worry this has been though out stiffened, boxed, and welded by yours truly. It's a friend of mines truck. He told me about the project and said there was only one person he trusted to do it. I used a 7x18x1/4" plate on the inside then a 7x7x1/4" square set like a diamond on the outside.

That's not me in the picture either that's my buddy with a reflective shirt on the flash from my phone makes him look clean

 

Clean is what you're calling it?

 

Or a Z-cut.

I kinda' like the way this was done:
https://www.ford-trucks.com/forums/4...ml#post3169824

Pop

 

I feel the same way Pop does.