How to spend a weekend…or Swiss cheese your frame.

[Ayrton]

I started on a few things this weekend and I thought you guys might want to see some of this. I am terrible at taking pics as I go so please bear with me…

Step one…Remove bed.

Removing the bed was surprisingly simple and it was easily removed by me with only one “buddy” helping. You will be surprised at the light weight of the bed. You will need to remove the bed bolts, three screws that hold the filler hose in place, unplug the wiring harness and a hose clamp on the filler hose.

[Ayrton]

Step two…removing or just moving things.

You will need to move some of the fuel and brake lines that run along the driver’s side frame rail. I simply unplugged the fuel vent lines (no fuel comes out) and moved them out of the way. (Be sure to plug off the hoses as you do not want fumes escaping)

I don’t really know if this step is really necessary but I like a clean surface to work with and I hate the fact that Ford uses such cheap undercoating. (I am sure you know it gets on everything) I took a simple putty knife and scraped off the undercoating. Once you get all you can get with the knife just take some WD-40 and wipe the frame down.

[Ayrton]

Step three…dealing with some “big *** rivets”

In the second photo you will notice four “big *** rivets” right above the axle and these are best dealt with after having an argument with your significant other. The rivets laughed at my air chisel and ate three titanium drill bits. So I broke out the grinder to show them who was boss…or so I thought. After grinding down the heads on the rivets, the little bastards still would not come out and I would have just left them in place if I could have, but you need to remove the two that are closet to the front of the truck. I went thru two more bits drilling out the rivets completely. One day I will run across the engineer who thought of these and I might have to spend the night in jail.

Once the “big *** rivets” are dealt with you will need to line up your notch in order to drill the holes. Once in place for drilling it should look something like this.

[Ayrton]

I am going to point out here that my C notch is sort of a prototype for the Supercrews and I have to make some adjustments as I go. I have talked with Stan (Ruslow) about the changes needed to simplify the install and Stan will make the decision on what to do.

So after drilling out 16 holes I am beat…I will add to this thread on Tuesday as I make more progress.

I already know that I totally suck at “how tos” so you do not have to point that out. However if you guys have questions or need photos of something, please ask them in this thread so we can eventually move this to the “how to” or “suspension” forum.

Oh yeah… here is a little peek at the front set up so far.

[2veloce]

Aryton your ideas on the Harley Truck continues to capture my attention. I am looking forward to the next chapter!

[TSDuke]

Looks nice. How's the heart of that monster coming along?

[Smoke This]

Chris, you cant leave anything alone can you? Everytime I talk to you your working on something else. I cant wait to see it when it is finished.

I will be calling you in a few, I have a question about my cam setup...or I will probably wait until this evening. Should be running in the morning!!!

[RobG]

Looking at those fancy control arms it looks like you're running one too many bump stops. What's up with that ???

[dubless]

Whips looking good man!

Hey... I know that front set-up;)

And I personally know about those 4 big a$$ rivets as well. Looks as if you're doing the drivers side.. just wait to you get to the pass side.

[CDN 02 HD]

that looks awsome keep us posted.

[Suds5.4]

Originally posted by RobG
Looking at those fancy control arms it looks like you're running one too many bump stops. What's up with that ???

I noticed the same thing.

[Krix330cic(NJ)]

i enjoy Swiss Cheese.. Cheddar too.

[Crockett59]

:b2:I'm a provolone man myself.

Chris, good job with the frame, looks to becoming along quite well.

[Venomous Mofo]

Dayum Chris, youre nuts

[Ayrton]

Step four…drilling

You can expect to spend a fair amount of time drilling all the holes needed and here are a few tips to help you keep your sanity. The diameter of the holes you are going to drill ( brand of C-notch may vary) is 7/16” and if you try and start with that size bit you will still be drilling when the 2007 models hit, so start out with something like a 3/16” and then step up to a 9/32” and finish with your 7/16” bit. This will allow you to go much faster and your bit will last longer. Most C notches will come with predrilled holes that will match up with certain factory holes for alignment and Stan’s is no exception. I found that using a 7/16” bit will keep things perfectly aligned until you can clamp everything in place.