Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Caution: Refer to Collision Sectioning Caution in the Preface section.

Important: The offset lap joint is used in areas that have compound angles that won't allow the new frame section to fit properly with an internal sleeve. In these areas use the offset overlap method, which will provide for some adjustment as well as allow for cut lines that may not be completely straight.

Important: The overlap of the offset joint repair can be as large as 100 mm (4in).

1. Cut two 75 mm (3in) slots into two opposite corners of the existing frame rail.
2. Slightly pry open the slots in the existing frame rail.




Important: The location of the 8 mm (5/16 in) holes will vary depending on the position of the frame rail overlap.

3. Drill three 8 mm (5/16 in) holes through each side of the frame rail sections.
4. Drill two 8 mm (5/16 in) holes through top and bottom of the frame rail sections.



5. Install the new frame rail section to the existing frame rail to create the offset lap joint.
6. Check the new frame rail section using three-dimensional measurements. Refer to Dimensions - Body , Measurements - Underbody .



7. Using a Metal Inset Gas (MIG) welder, plug weld the new frame rail section to the existing frame rail.

Important: Use a 25 mm (1in) stitch weld to avoid minimal heat distortion.

8. Using a MIG welder, weld a 25 mm (1 in) stitch along the overlap joint.