TheSamba.com :: View topic - Cross Brace Metal Replacement (Front) Metal Repair

Wed Jul 09, 2025 2:46 pm

Hey all,

I've replaced a lot of metal on previous rides, Im prepping to replace the front cross brace on my bus, it's fairly roached out so most of it will crumbled right out with gloves and pry bar, odd because the floor is super clean and mostly stock.

Anyways, does anyone have any tips?

Im sure once I get in there with a cut off wheel, pry bar, hammer, and reciprocating saw, and drill.... it should be self explanatory. Not concerned about the center heat tube, that was roached and getting pulled out.

I think what I am curious about is the amount of spot welds, any areas that may be harder to find or tackle? Spot welds always get me! :twisted: Sigh, welding overhead... soooo much fun.

This bad boy:

:?:

Wed Jul 09, 2025 3:00 pm

Just make sure to get a quality repro part - the fitment car vary significantly. Get the old one cut out, clean everything off, grind all the spot welds flat. If you won't have a spot welder, you can drill/punch holes and plug weld it.

Wed Jul 09, 2025 5:58 pm

thom wrote: Just make sure to get a quality repro part - the fitment car vary significantly. Get the old one cut out, clean everything off, grind all the spot welds flat. If you won't have a spot welder, you can drill/punch holes and plug weld it.

Thanks! projects like this wishing I had a lift. But I'll get it jacked up high enough to work safe and efficient. Yeah aftermarket panels are always a hit or mis. I have some outriggers to do as well, I rough fitted one so far it fits great, I buy almost everything from WolfsBurg West, unless its something custom in regards to lowering kits, etc.

Thanks for the heads up, I'll try to get some good photos and post when finished, might be a good reference thread since I didn't see many.

8)

Wed Jul 09, 2025 6:26 pm

I did mine while on ramps. But I also had my floor completely out also. If your floor is toast clean everything out then rebuild the structure while you have room to move.

Wed Jul 09, 2025 6:46 pm

pondoras box wrote: I did mine while on ramps. But I also had my floor completely out also. If your floor is toast clean everything out then rebuild the structure while you have room to move.

Nice, ramps would also be ideal, I have jacks and wood, and such. Floors are solid, but I will definitely be taking advantage of cutting out, cleaning, welding, treating, etc. any areas that need to be addressed nearby the cross member, frame rails are really clean, its odd whats solid and what needs work on this bus, it feels like everything is opposite, but who knows what previous owners and lives it had.

This was later on my build list, but my brake lines which are nearly finished run through the cross brace, I already have it ready to weld in, just need to get the dirty deed of cutting out of the old stuff.