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Rodney, It's always better to take the time now, and figure this out.
I'm not sure about the PO repair, maybe just not understanding the picture.Are you saying the frame is straight untill the repair starts under the cab...then somehow comes back in ...Frame cross measurements ok?..Sounds like a mis-aligned rt frame-rail by your desccription.
Might not make any difference,as long as crossmember is put in square with a good square front frame..I can see your concern as your taking measurements ..front to rear at the crossmember mounting,..and the rt rear does not reconcile,but those points your measuring to are compromised by the po's repair.
You can still mount the crossmember by using the c/l-p/l method,
or ,if your a nut like me, might look for another frame cos you don't like the idea of riding on a bent rail.Keep us posted, Good Luck!
Damn I had to laugh at that one. No, it found a new home a couple of weekends ago. I'm hoping they will take care of this without any problems. Hell, I've spent enough time crawling and measuring that frame that I think I could be certified as some sort of "bone head expert" . I'm calling them this morning as soon as I get a chance. I'll let you know how it goes.
If great care is not taken welding on a frame (or assembling a crossmember) can cause it to take on some very strange shapes. Sounds like you have verified that your's is relatively straight (Altho 7/8" out of square on the diagonal measurements is a bit much in my book), so as you I would suspect the crossmember. Shouldn't be difficult to verify.
Your luck sounds like mine, if there is one bad part in 500, I'll be sure to get that one...
Ax I was thinking the same thing about getting the one bad CM out of the bunch...just my luck. I just wish I would have realized it a lot sooner. I must say that at least TCI has stepped up to the plate and they are sending me a new crossmember kit and shipping my original one back at their cost and with no headaches. Now a days you hear a lot about companies trying to back pedal when it comes to taking care of their customers. Thanks to all the help I got on this problem from my fellow FTE members. Hopefully things will go a little smoother for a while at least.