Mechanic cut frame to fit headers, how bad is it? - The 1947 - Present Chevrolet & GMC Truck Message Board Network

Brody54 · 01-10-2024, 06:41 PM

Hey all, it’s been awhile and my truck has been getting worked on over a year for an engine/ tranny swap. The engine came from a 69 Camaro but same thing, small block Chevy and turbo 400 out and in. Just higher performance and a 383.

Anyways the mechanic kept the headers from the Camaro and cut the frame to make them fit. I’m not happy at all and looking to get a second opinion. How bad is it, and my concern is the frame cracking eventually.

GASoline71 · 01-10-2024, 06:57 PM

I don't think I'd call that dude a "mechanic". Especially if a SBC engine swap took over a year. But the frame will be fine. It appears he drilled a big hole to get a saw blade in there. There are a couple of spots that should get welded up a bit. It's unsightly, yet repairable.

Gary

**HO455** · 01-10-2024, 07:23 PM

Personally I would be concerned with cracks starting in the spots with red arrows and possibly at the yellow arrow too. The photo makes it had to tell if the spot at the yellow arrow has any sharp corners. The mechanic had the rights idea when he drilled the hole at the front end but lost it in execution. Those 2 cuts from the saw blade in the drilled spot are prime places for cracks to start.

And if it was my truck I would weld in a patch piece similar to the green out line in the second photo. The PO of my Burban cut the frame but with a torch which didn't leave any sharp corners. I only had to grind the slag off and make sure there were no sharp corners for cracks to start. Without measuring I don't believe the cutout in my Burban's frame is as deep into the Cee of the frame as yours is, but it is close.

57larry · 01-10-2024, 07:40 PM

you need to sue "the mechanic"

Keith Seymore · 01-10-2024, 07:43 PM

Quote:

Originally Posted by HO455

Personally I would be concerned with cracks starting in the spots with red arrows and possibly at the yellow arrow too. The photo makes it had to tell if the spot at the yellow arrow has any sharp corners. The mechanic had the rights idea when he drilled the hole at the front end but lost it in execution. Those 2 cuts from the saw blade in the drilled spot are prime places for cracks to start.

And if it was my truck I would weld in a patch piece similar to the green out line in the second photo. The PO of my Burban cut the frame but with a torch which didn't leave any sharp corners. I only had to grind the slag off and make sure there were no sharp corners for cracks to start. Without measuring I don't believe the cutout in my Burban's frame is as deep into the Cee of the frame as yours is, but it is close.

Agree; I would probably weld a shaped plate on top to provide a little reinforement but mostly to clean up the appearance.

K

54blackhornet · 01-10-2024, 08:01 PM

Question? Could you drill holes further outside the cut and bolt a plate on top for rigidity and removable ?

Sicklajoie · 01-10-2024, 09:00 PM

Clean job with mine, looks like the factory did it.

BRL · 01-10-2024, 09:40 PM

FerKrissakes get some headers that clear the frame to begin with!

...then get a new mechanic.

But since you're already in this situation, do like others have said and reinforce the frame, otherwise every time you start pulling some torque out of that 383 the thought will be in the back of your mind.

...just my worthless opinion.

**jerry moss** · 01-10-2024, 10:30 PM

Quote:

Originally Posted by HO455

Personally I would be concerned with cracks starting in the spots with red arrows and possibly at the yellow arrow too. The photo makes it had to tell if the spot at the yellow arrow has any sharp corners. The mechanic had the rights idea when he drilled the hole at the front end but lost it in execution. Those 2 cuts from the saw blade in the drilled spot are prime places for cracks to start.

And if it was my truck I would weld in a patch piece similar to the green out line in the second photo. The PO of my Burban cut the frame but with a torch which didn't leave any sharp corners. I only had to grind the slag off and make sure there were no sharp corners for cracks to start. Without measuring I don't believe the cutout in my Burban's frame is as deep into the Cee of the frame as yours is, but it is close.

I agree, he chopped/ butchered your frame, get the correct "truck" headers and get the frame repaired or it will crack. many years ago my cousin bought a really nice K20 with a big block in it and the frame looked about as bad as yours. we pulled the motor and the front clip, cut patch pieces from a parts truck and I took it to the muffler shop where I work and welded them in top and bottom. cleaned the welds on the top side, primed and repainted it. from the top side you could not tell it was repaired but it still had a good bead on the underside.

LS short box · 01-10-2024, 10:34 PM

I would get in there with a die grinder and get rid of the drill hole and then a make a plate 3/16" contoured as needed to allow room for the header. Butt weld it in and grind flush.
As shown above it would of been much better to pull the header and and die grind the frame a bit until you had good clearance.

**Steeveedee** · 01-10-2024, 11:36 PM

The guy never hear of "tuning dings", methinks. Dents in the headers wouldn't have hurt performance much (if at all), and the frame would have been fine, left alone.

**truckster** · 01-10-2024, 11:50 PM

Quote:

Originally Posted by 54blackhornet

Question? Could you drill holes further outside the cut and bolt a plate on top for rigidity and removable ?

A bolted plate is not going to give it much strength. It needs to be welded.

3drburb · 01-11-2024, 12:48 AM

It should be fixed as said above and you should also look around to see what else the butcher hacked up for what should be a simple install.

**71CHEVYSHORTBED402** · 01-11-2024, 01:36 AM

Wow. Someone really wanted those headers.

novaX522 · 01-12-2024, 12:08 AM

My truck has Hedman headers, not sure what they are supposed to fit. Previous owner clearanced the frame. I thought it was a decent job.
I agree with the others, I would use cardboard as a template on yours and make a patch piece and weld it in. From the pictures, it doesn’t look like much clearance is needed for your headers. Also agree not to use that mechanic 🤪 going forward.

72SB · 01-12-2024, 06:16 PM

This would qualify as a "hack" mod. A good welder can box in that area and clean it up. May have to pull the header on that side for welding access. This can be fixed to look right and restore, actually improve, structural integrity of the frame.

01-10-2024, 06:41 PM	#1
Brody54 Registered User Join Date: Apr 2022 Location: San Diego California Posts: 3	Mechanic cut frame to fit headers, how bad is it? Hey all, it’s been awhile and my truck has been getting worked on over a year for an engine/ tranny swap. The engine came from a 69 Camaro but same thing, small block Chevy and turbo 400 out and in. Just higher performance and a 383. Anyways the mechanic kept the headers from the Camaro and cut the frame to make them fit. I’m not happy at all and looking to get a second opinion. How bad is it, and my concern is the frame cracking eventually. Attached Images

01-10-2024, 07:23 PM	#3
HO455 Post Whore Join Date: Feb 2016 Location: Portland Oregon Posts: 10,844	Re: Mechanic cut frame to fit headers, how bad is it? Personally I would be concerned with cracks starting in the spots with red arrows and possibly at the yellow arrow too. The photo makes it had to tell if the spot at the yellow arrow has any sharp corners. The mechanic had the rights idea when he drilled the hole at the front end but lost it in execution. Those 2 cuts from the saw blade in the drilled spot are prime places for cracks to start. And if it was my truck I would weld in a patch piece similar to the green out line in the second photo. The PO of my Burban cut the frame but with a torch which didn't leave any sharp corners. I only had to grind the slag off and make sure there were no sharp corners for cracks to start. Without measuring I don't believe the cutout in my Burban's frame is as deep into the Cee of the frame as yours is, but it is close. Attached Images __________________ Thanks to Bob and Jeanie and everyone else at Superior Performance for all their great help. RIP Bob Parks. 1967 Burban (the WMB),1988 S10 Blazer (the Stink10 II),1969 GTO (the Goat), 1970 Javelin, 1952 F2 Ford OHC six 4X4, 29 Model A, 72 Firebird (the DBP Bird). 85 Alfa Romeo If it breaks I didn't want it in the first place The WMB repair thread http://67-72chevytrucks.com/vboard/s...d.php?t=698377

01-10-2024, 07:40 PM	#4
57larry Registered User Join Date: Nov 2007 Location: Indianapolis Posts: 1,160	Re: Mechanic cut frame to fit headers, how bad is it? you need to sue "the mechanic"

01-10-2024, 08:01 PM	#6
54blackhornet Registered User Join Date: Jul 2008 Location: Eastern Oregon Posts: 2,263	Re: Mechanic cut frame to fit headers, how bad is it? Question? Could you drill holes further outside the cut and bolt a plate on top for rigidity and removable ? __________________ 71 C-20 07 Magnum RT AWD

01-10-2024, 09:00 PM	#7
Sicklajoie The Niner Join Date: Nov 2010 Location: Broad Brook, CT Posts: 2,491	Re: Mechanic cut frame to fit headers, how bad is it? Clean job with mine, looks like the factory did it. Attached Images __________________ "A good racer is one whose head is in communication with his balls." - Richie Evans 1970 C/20 - 402/TH400/3.54s - 74K miles 2003 GMC Sierra 2500 - Wheatland Yellow Niner Progression Thread: http://67-72chevytrucks.com/vboard/s...d.php?t=697183 Classic Trucks article: https://www.motortrend.com/features/...et-c20-driven/

01-10-2024, 09:40 PM	#8
BRL Registered User Join Date: Jun 2014 Location: Tahuya WA Posts: 517	Re: Mechanic cut frame to fit headers, how bad is it? FerKrissakes get some headers that clear the frame to begin with! ...then get a new mechanic. But since you're already in this situation, do like others have said and reinforce the frame, otherwise every time you start pulling some torque out of that 383 the thought will be in the back of your mind. ...just my worthless opinion.

01-10-2024, 10:34 PM	#10
LS short box Registered User Join Date: Jun 2015 Location: Carlos MN Posts: 1,929	Re: Mechanic cut frame to fit headers, how bad is it? I would get in there with a die grinder and get rid of the drill hole and then a make a plate 3/16" contoured as needed to allow room for the header. Butt weld it in and grind flush. As shown above it would of been much better to pull the header and and die grind the frame a bit until you had good clearance.

01-10-2024, 11:36 PM	#11
Steeveedee Who Changed This? Join Date: Jan 2013 Location: Simi Valley, CA Posts: 10,114	Re: Mechanic cut frame to fit headers, how bad is it? The guy never hear of "tuning dings", methinks. Dents in the headers wouldn't have hurt performance much (if at all), and the frame would have been fine, left alone. __________________ ~Steven '70 Chevy 3/4T Longhorn CST 402/400/3.56 Custom Camper Simi Valley, CA

01-11-2024, 12:48 AM	#13
3drburb Registered User Join Date: Jul 2011 Location: Kent, WA. Posts: 834	Re: Mechanic cut frame to fit headers, how bad is it? It should be fixed as said above and you should also look around to see what else the butcher hacked up for what should be a simple install.

01-11-2024, 01:36 AM	#14
71CHEVYSHORTBED402 Senior Member Join Date: Feb 2009 Location: Northern Nevada Posts: 7,129	Re: Mechanic cut frame to fit headers, how bad is it? Wow. Someone really wanted those headers. __________________ Tony 71 Custom Deluxe, SWB, 2WD, 402, A/C. I developed an assm. guide "kit" for restoring it from ground up. With assys, the guide accts for 1000s details such as OEM identifications& part numbers, written in short order. 700+ images include assm, illust., charts, and points of interest. Much of the info. applies to all 67-72 GM trucks, and to a lessor degree all 67-72 GM vehicles. My build thread, and more on the guide https://67-72chevytrucks.com/vboard/...d.php?t=730025

01-12-2024, 12:08 AM	#15
novaX522 Registered User Join Date: Oct 2023 Location: Waterloo Iowa Posts: 243	Re: Mechanic cut frame to fit headers, how bad is it? My truck has Hedman headers, not sure what they are supposed to fit. Previous owner clearanced the frame. I thought it was a decent job. I agree with the others, I would use cardboard as a template on yours and make a patch piece and weld it in. From the pictures, it doesn’t look like much clearance is needed for your headers. Also agree not to use that mechanic 🤪 going forward. Attached Images

01-12-2024, 06:16 PM	#16
72SB Registered User Join Date: Apr 2022 Location: Moorpark, CA Posts: 702	Re: Mechanic cut frame to fit headers, how bad is it? This would qualify as a "hack" mod. A good welder can box in that area and clean it up. May have to pull the header on that side for welding access. This can be fixed to look right and restore, actually improve, structural integrity of the frame.



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