Before you take anything apart mark each and every hole or mount being used. You'll want to weld in backer nuts for the crap you'll no longer have access to once it is boxed. X out any other unused holes and fill them while you have the tools out. Cleans it up a bunch and keeps less water and junk out.
Look at the fuel and brake systems... see what needs to be done there...
Whire-wheel and and rust treatment for cleaning everything up prior to fabing. Clean metal is much easier to work with through-out this ordeal.
It's a PITA.... I've been working on my frame off and on for 3 months. I agree 100% with the cross braces.... if you think you need 3 add 5. Then you can remove your old cross members, if you're boxing in with a single long plate. I don't have a frame table but I leveled mine on jack stands and heavy weights on each corner. As stated before, check you're level every few welds. I have had to adjust things a few times.
Stitch the boxing plates about every 12" alternating to each side or wait and cool off, if doing one side at a time.
Once the plates are stitched. I'd start tacking up the new cross members. Depending on what thickness of material you boxed with, I would reinforce the weld area with an added plate x2 the area of the cross member. pretty much like a big washer on the end of the new cross member. There's a name for it, but it slips my mind right now. Tack it up only. If everything is square and level still. Start the final welding. One inch at a time.......
If I had to do it again.... I would buy a complete frame just for the the time savings alone...
Last edited by Lugnutzz3000; 12/30/2012 11:51 AM.
After searching for a year I found the next project!
46' 1/2 ton in pieces! took 2 trips to get it home, but most of the hard work was already done!!!
-jerry
"Phil" the 46' 
