Rear Fuel Tank Crossmember Replacement

Replacing the Fuel tank crossmember the Right Way

[@Djinantonek]

I did mine just this way. Right down to the way you got the stubs out of the frame. Worked great, Straight tube was no issue. 3" tubing is what you need, yes. Great job.

[@stevemas4966]

Your video was a big help, thanks

[@andrewfredrick7017]

thanks for this video! just did mine today. local supplier was out of 11g. 3" so i got 2-1/2" i.d. with a .0200 wall and is 2.875" od. took a while to grind the old one out and segmented it with a sawzall. made the hammer and chisel work a little easier. welded in the new one with no issues. made some 1/4" thick shock mount flanges and salvaged the gas tank supports. going to do the rear ones next. all that rust and i wash mine frequently during the winter, but not enough.... apparently.

[@rvtek4695]

Great job, these trucks have an issue with this area for sure

[@KenMrKLC]

I hate to be "That Guy" But based on your thumb nail I guess me buying a replacement tube with the proper angles of the gas tank to be secured properly and level is the "Wrong Way"?

[@danielmason1326]

Great video.. Actually makes me think i can do it myself.. Thank you soo much for sharing your knowledge :)

[@rvtek4695]

Thanks!

[@jamesguralski5156]

Great vid! Best tool to cut the tubes out is a plasma Arc cutter! usually the new tube comes with plate to actually well the plates to the frame and then you actually well the pipe to the plates. I guess it depends on what your order.. The new plates of metal also strengthen the frame. My frame has a lot more cancer (rust).

[@terrygraves4736]

Yes, I love my plasma cutter

[@jimmyschmidt14]

i wonder if you could bake that tube yourself in an angle iron or c channel shape with 3/16 plate.

[@AZ-kr6ff]

What kind of insurance covers liability when welding on a vehicle frame? I run a small structural welding business, fully insured, but I'm always very hesitant to touch a vehicle frame. Work looks good!

[@terrygraves4736]

I'm not sure, when I was in business I had insurance that covered everything we did, I was always hesitant about repairs to hitches ect.

[@AZ-kr6ff]

@@terrygraves4736 Yeah, I'm covered in any structure up to 5 stories, but my policy won't even allow me to weld on a bumper

[@jessyshaq23]

Anyone know if the rear shock mount cross member is also 3" diameter?

[@terrygraves4736]

Yes it is

[@jjrock5]

How much did you have to grind off the frame to see the tube to frame mating line? I’m grinding now but I still don’t see the tube outer diameter so i can then use my air hammer to remove it. I’m using a 4-1/4 angle Grinder with a grinding wheel. Been at it for a while and still can’t see that line to know that I’ve ground through the weld. Thanks.

[@numbrenine9414]

great video, however it seems to me (as they all seem to rust out in the same place) that the problem is the deep chanel in the gas tank holds water , dirt, salt, whatever, causing the crossmember to rust out, seems a design change, or useing earlier style tank n crossmembre (if possible) would be better

[@rvtek4695]

I agree, It would have been a simple thing for GM to fix for sure.

[@ChiNguyen-wf1qt]

The original has some drilled holes. Is it for water to run out or for something else?

[@terrygraves4736]

Not sure on that, from the factory they sometimes plug wire ties into holes to hold the various wiring

[@Trucks-kt9gt]

What thickness is your tubing? I'm going to replace mine. Much cheaper then ordering a new one that's for damn sure

[@rvtek4695]

I used what I had here, 3/16 tubing

[@Trucks-kt9gt]

RVTEK perfect thank you for sharing your knowledge. You did a great job I forgot to mention. I love my old truck and want to keep her

[@6glenn9]

3 inch exhaust pipe does a great job. Easy to work with even if you want to put the bend in.

[@jg7017193]

hydroform steel that was their sales pitch

[@rvtek4695]

I ground till I was flush with the frame rails

[@JC-oz6xn]

Man, is your shop anywhere near Savannah?

[@terrygraves4736]

Sorry upstate ny

[@bkress9638]

What is the length you cut the pipe to?

[@rvtek4695]

I don't recall the exact measurement, but it was 1/4 longer than the frame rail so I had something to weld to

[@Trucks-kt9gt]

I'm going 44 inches. A little over 2 inches longer but this way I don't have to make sure it's perfectly centered lol. I can always cut access off when I'm done but 42 inches would be better to be honest with you

[@rvtek4695]

I had lots of room to mess with it, plus I didn't have a real long piece to begin with, lol

[@jerrydanner5279]

You could have got a cross member on e bay for 167.00

[@terrygraves4736]

Yup, I could but I'm a builder, I had the steel so why buy

[@elvis2577]

I just got one from ebay.i think it was $90

[@curtisbrown7239]

Cannot hear you

[@rvtek4695]

Sorry, my videos are one "takers" I don't use mikes ect.

[@mrrj7004]

u be aight