Repair of Frame / Body Mount Holes

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Once the body was separated from the chassis, rust damage to the body mount holes was apparent. This was repaired prior to re-assembly in order to provide a solid base.

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I started with 2" diameter, 1/8" thick washers purchased at the local hardware store. I then used a hole saw to create the correct inside diameter in the washers for the body mount bushings.     After this, I used a die grinder to bore out the existing (and rusted) frame hole to accept the outside diameter of the new washers. Be sure to leave material in the frame to provide a snug, press fit between these components!     I then welded the washers flush with the frame, and used a grinder to flatten the welds. A little Eastwood Rust Encapsulator sealed the deal.