Re: Front crossmember


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Posted by Paul (in NY) on Wednesday, April 25, 2007 at 08:40:27 :

In Reply to: Front crossmember posted by igor on Wednesday, April 25, 2007 at 07:08:44 :

I use this method to remove any large rivets on the frame and also the rear brake backing plates;

1. Take a 4.5" angle grinder with a 1/16" kerf cutoff wheel. With the angle grinder and cutoff wheel come in from side and cut the head off the rivit as close as possible.

2. With the angle grinder and a flap type abrasive grinding disk,

grind the end of each of the rivets smooth where you just cut the head off.

3. You will now see the outline of the rivet that has to be removed. Get Dead Center on each rivet and make a nice deep center punch.

4. Now drill into the rivet body towards the rear of the rivet. Start with a 1/8" drill bit. Drill the first hole so you are to a depth that is past the frame. Then with a 1/4" drill bit open the hole to 1/4", then with a 5/16" drill bit open the hole to 5/16" and finally with a 3/8" drill bit open the hole to 3/8". Each time you enlarge the hole, be sure to drill all the way to the bottom of the first pilot 1/8" hole. Of course the size drills depend on the diameter of the rivet being removed. You want to drill it out so only a small portion of the rivet wall is left. This way you dont go past the rivet sides and drill into the original hole. Also by stepping up in drill size slowly, you have less chance of wandering out of the center of the rivet.

5. You will now have a hole, that is the largest diameter possible and proper depth to clear the holding material. Use a pair of Large Vise Grips to hold the a flat punch that just fits the drilled hole, so you eliminate the chance of hitting your fingers. Now with SAFETY GOGGLES and GLOVES, take a hand sledge and wack the punch. The first blow will have a ring, the second and third blows will have a muffled thud as the rivit moves out. I find it takes about 4 blows and the rivit is out.

The reason for drilling the holes is this. If you try to drive on the flush cut off rivet body, each blow will cause the rivit to expand just a little in the already tight hole. The more you have to drive on it, the more you expand the rivit and make it even tighter and harder to drive out. By drilling the largest hole possible, you are driving on the inside of the rivit past the holding material so that any expansion will not expand the rivit and bind it in the hole.

On my PW's and WC there is also some welds on the front cross member to the frame that must be cut with a cut off wheel. Apparently, not all PW's have these welds. Some people report only rivets. But every PW I have ever owned has also had these welds.

Paul



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