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A couple of the holes on my body mount brackets are rusted and the holes are twice the size they should be for the rubber bushings. What is the best way to repair the holes back to the original size?
Use a 1/8" thick steel plate. Cut a hole with the proper size hole saw. Weld onto top of frame support. Unfortunately sometimes the frame supports are so bad they should be replaced or a new unit completely fabricated.
If you have any industrial fastener houses nearby you may even be able to find a nice washer to fit the mount and weld that onto the top of the frame support. I made a bunch for a friend with the hole saw method but it is a pain even with a drill press.
we sell a ton of 1 1/2" flat washers to body shops and garages, they fit most ford and chevy body mount ... got enough old fords, i've used a few myself.
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.