Rear Frame Horn Repair

[71BRONCO71]

Some of you may remember the picture of my bumper laying on the ground. The vibration from the spare tire wore the frame out and eventually cracked it.
I made a repair from another frame years ago but those frame horns were bent. I did my best to straighten them out but they were never right.
found a "repair" kit for the frame on ebay.
So last night I decided to start the repair so I can make a rear bumper.

[71BRONCO71]

I cut the old horns off that I plated and got started mocking up the new horns. The upper part will weld on no problem, the lowers still need to be bent a little more. I am going to take my time to get these things right the first time.
I made a jig out of all thread and a 1by.
the opening is 4" tall and the span from eye to eye is 26.6".

[Action]

I like the look on your face in the first picture.....

[71BRONCO71]

Taking small bites. I got the uppers hung.

I didn't cut the frame square at all, so I'm going to have to fill the gap when welding. I will plate the outside and no one should know.

I tried so hard to get the horns level/parallel but i failed every time.. my frame isn't square anymore and my suspension isn't level.
so I shoved a 2x3 piece of lumber inside the frame and clamped it. That worked perfectly.

[71BRONCO71]

I snuck back out to the garage for a little bit last night after everyone went to sleep.
I didn't like how the factory frame was tapered. I decided to straighten out the lower horn. That way I can shove the 2x4 steel inside more than 2 inches.
lowers are tacked.

[904Bronco]

So much fun Ryan to make something right ...

[crawlin68]

I remember coming around the corner to find you standing in the middle of the road staring at your bumper laying on the ground. LOL. Nice that you are fixing right. Good job man!

[71BRONCO71]

Buzzed all the brackets together and added some diamond gussets across the weld.

Now it time to start building a new rear bumper.

[crawlin68]

Looks really man. You will never have another problem with again!

[Formerjughead]

I ............ I decided to straighten out the lower horn. That way I can shove the 2x4 steel inside more than 2 inches........

The first couple of inches is where all the fun is...

[Broncrick]

Looks really man. You will never have another problem with again!

looks good bud!