So the hole-saw bits I have went through quite a few projects by this point.. and while drilling the frame for the swaybar tube I managed to snap all of my drill bit inserts, as well as chip off some remaining teeth lol so I have a single 1 1/2" bit coming from amazon today so that I can make some support plates to secure the tube to the frame.
I drilled the passenger side one size larger on purpose knowing very well that I would not spend the time needed to accurately measure and lay out the holes (and frankly, even if I did, drilling laying down under the car would probably get these offset anyhow). The idea is to use the 1 1/2" hole saw bit to cut 4 plates that fit snuggly around the weld-in tube. I will then tack the drivers side in place and use the slop in the passenger side hole to square up the tube best I can. I don't believe this is HYPERCRITICAL to get 100% square, but because the clearance from the arms to the frame will be fairly tight, I don't want either side making contact as it goes through the arc of its motion because its not close to straight.
I also don't think the 2 holes adjacent to my new frame holes NEED to be plated since the new hole will have a tube going through it and welded on both sides, so it's not like the frame will be any weaker there, rather stronger if anything, but I still plan on cutting my support plates oversized so that they would also cover up at least one of the holes on each side.
Time to put the plasma cutter to some actual use!
We have a beach trip coming up for my brothers Birthday and the rig will be out on the sand for 2-3 days , and it is a 3 hours away, so I am in full prep mode to make sure everything is welded and also painted before I expose it to salty air. Got a can of Steel It paint that I'll throw on after all the welding is done, and also see if I can get my hands on some of the inner frame treatment spay my brother uses at work to treat the frame from the inside after it had some welding done from the exterior in hopes of reducing rusting and corrosion.
The plan for today and tomorrow is to cut the 4 support plates for the sway bar, cut the 2 gusset strips to reinforce the drivers side front diff mount I have laying around and cut off and clean up the body mounts.
I'm considering cutting off the original bump-stop mounts since I don't ever see a need to go back to them.. but they also dont appear to be in the way of the sway bar arms so I may just end up leaving them. My initial bump-stop test fit looks promising, but I need to pull the springs to fully cycle my suspension to full-bump and verify i start making contact at least 1" before the shock bottoms out. Before I do that, I may also slide the rear axle back just a tad bit more to fully center it in my new wider opening with the rear bumper cut down... but I feel like i really screwed up when making my adjustable rear links.. I made them to factory length at half-adjustment on the heims.. and really should have made them slightly longer. I don't know how far I can safely run the threads out on them without risking pulling/stripping threads under load, and definitely feel like I'm starting to get close.
That's all for this morning's update.. sorry.. not pictures, just some boring documentation stuff for myself down the road
