99-07 Silverado / Sierra fuel tank crossmember rotted out? How to WELD in a REPLACEMENT

This is the 19th video to my 2005 gmc sierra. This episodes progress is related to cutting out the old fuel tank cross member and getting the new one fit in.
First song
Song: John Dee, Litil, Elle Vee - Set It Free [Arcade Release] Music provided by NoCopyrightSounds Free Download/Stream: ncs.io/SetItFree Watch: ncs.lnk.to/SetItFreeAT/youtube

[@bdubs6205]

I bought the eBay ones too! Actually just did this exact job this past weekend. All too used a saws all to remove the crossmembers but then used a 3 1/4” hole saw to remove the tubes from the frame. Had to drill 8 holes. On the passenger side outside part of the frame I had to make it more oval shape to get the tube to slide in fully. But then just welded the new tubes to the old frame. It worked perfectly. Didn’t use any of those extra plates they gave as the steel on the frame was still good. But crossmembers we’re rotted to no end. Spray painted the bare parts. Took a needle scaler to the rest of the frame. Ended up using surface shield to treat everything. It’s a wet treatment. Mixed black graphite powder in so when I sprayed it on it looks like I painted it black! Anyway, nice job with how you did it. I left my cab on. Also had to do all new cab mounts. Amazing how these things rust out! 2004 Silverado 1500. Take care.

[@Iaulus]

Thanks for the hole saw idea about to do mine and not sure why I didn't think about it. Was about to get a die grinder to get it out but this seems like a way better idea!

[@bdubs6205]

@@Iaulusit worked incredibly well. I saw people using angle grinder, torch, etc. I thought…there has to be a better way! And sure enough that hole saw size fits perfectly. Good luck to you!

[@user-qq5us6gv7c]

Was wondering what is involved in removing the cab from one of these trucks. I'm getting ready to do these cross members on my 2003 long bed.

[@alecaagaard]

This is another great way to tackle the task. I thought about the hole saw idea but didnt have one handy, plus i generally prefer to weld a straight line versus a circle. I wish i had a plasma cutter, as that would help big time too. Either way, sounds like yours came out well, and if its strong, who cares how you did it!

[@alecaagaard]

Do you have access to a lift? if not, maybe a large amount of cribbing or dunnage that can get the cab above the rear portion of the frame to roll it out. Removing the cab is a short afternoon job. Your biggest headache is the parking brake cable, and if thats already not functional or you dont have a desire to keep it, you just saved at least an hour of time. Your other key points are either taking the fenders off or unbolting them from the core support, disconnecting the wires from the cab to the fuse box, shifter cables, grounds and bolts. I have a video that covers most of this if you would like to check it out. kzbin.info/www/bejne/mIW7dImuqtWphK8si=evfEehTBZ5UYvi3X

[@danielcovarrubias9751]

Where did you buy the crossmember?

[@alecaagaard]

This is an Ebay one. Cheapest one on there if I remember correctly. See if this link works. www.ebay.com/itm/254627442704?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=BBRO_a0KS2C&sssrc=2349624&ssuid=sf7tqedyqlc&var=&widget_ver=artemis&media=COPY

[@ManyProjectsLittleTime]

What is involved in removing the cab and front clip from one of these trucks?

[@alecaagaard]

Check out my episode 3 or 4 video, shows how I removed the cab. Wiring and seperating the core support. Pretty easy.

[@ManyProjectsLittleTime]

@@alecaagaard Thanks I will.