Does anyone have any drawings or pictures that show how the bushings/retainers attach to the frame components? I picked up a rad support from the junk yard and only the mounting holes are rusted out. I'll be welding new supports on it, and need to know what shape the hole should be. It appears that for some reason, there are hexagonal-shaped holes there, and I don't know why. I have looked at dozens at the junkyard to try and figure it out, but they are all rusted beyond recognition. I can get this bushing kit from Jeffs Bronco Graveyard, but I need to know how it attaches to the support/frame.
Radiator Core Support Mounting Kit-Broncograveyard.com

 

They are sort of oblong, kind of like a slotted hole, to allow the CS to be moved a bit from side to side. A regular hole that is a bit larger than the bolt will be just fine. I don't think it's that critical.

 

I have the same rusting problem on a 03 Expedition. I'm wondering if it is possible to have 2 brackets made and attach them to the frame and the bottom of the radiator. This should give it a lot of support. Has anyone tried this approach.

 

Do you understand that frame flex is a big reason that the cab is rubber mounted?

There are frame saver kits to repair the horns, but no one I know makes a repair panel for the bottom of the radiator support.

 

I didn't think that the frame would flex enough to be a concern. The brackets would help to support the radiator and wouldn't cost much. Any metal fabricator should be able to make 2 brackets. Do you know if there is an issue with galvanic corrosion if the radiator touches the frame?

Thanks for you reply.

 

Can't you replace the core support and mounts? Idk about an expedition but these OBS trucks have tons of frame flex.

 

I can replace the core support but the entire front of the truck has to be removed and it costs over $1200. The truck is an 03 and I'm going to buy something else in 6 -9 months. Its in good shape but I had it for years.

The radiator isn't moving yet and I thought if the brackets were attached to the cross member it would help.

Thanks