Question about 1996 Ford F150 Regular Cab

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I have a 1996 F-150 XLT with the 300-6 and a 5spd. It has approximately 184k on it and I recently installed a 6inch rough country suspension lift with shocks and extended brake lines included. I have 37 x 12.50 Goodyear Wrangler Mt/rs on the truck. I have a truck box with approximately 200lbs of equipment and supplies for trail repairs. I also carry a fullsize spare. I was wheeling with a large friend of mine (about 450lbs) and I went over a waterbar to quickly and cracked the frame about an inch behind the passenger side spring bucket(the crack runs through the brake line hole and to the right of the smaller hole by the bottom of the frame. I have tack welded the frame back in place and I am currently looking for advice on repair. I am currently thinking of using an right angle die grinder to prep the frame with 50grit paper to remove the rust on the inside and outside of the frame. I can attack the bottom of the frame in this same mannor but the top is going to be the harder spot to reach. Will it get by with just teh bottom being repaired until I install the body lift when I replace the radiator support and front fenders? Any and all advice will be extremely helpful. Thanks in advance.

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I suppose that the required quality of the frame repair depends partly on how much you plan to stress the frame before you have the opportunity to do a complete repair. I suggest you take it easy on the truck (don't go wheeling) until the frame is fully repaired and reinforced.

Posted on Aug 23, 2010

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