Hi, new to the forum. I am prepping a newly acquired 2001 F150 XLT extended cab for inspection and noticed rust on the ends of what I guess would be called the cab supports or cab braces under the cab. These are the channeled braces that run from one side of the cab to the other. I checked with the inspection station and they stated the truck would not pass as is. I have been trying to find replacement or repair pieces that I can weld in but have found nothing on the web. I'm assuming I'll end up having to fab something unless someone has a solution/part suggestion. Any information would be greatly appreciated.

Thanks!

 

Welcome to the forum. I'm seeing both a bad support and a bad crossmember. I don't know of anyone that making them for the aftermarket but doesn't mean someone isn't making them. I'd bet there's some NOS out there but finding them can be a PITA and timely. A salvage yard would probably be your best bet but you'd have to find ones that aren't already in the same condition since I'm guessing you're also a rust belt resident? If your just looking to get the truck on the road instead of a restoration, it looks like all you need are the ends. Maybe 10" to 14" where they join the frame rail. Ford has on one of their web sites the welding requirements for this work if you're in a state that requires OEM spec'd repairs to pass inspections.

 

River1, thanks for the info. You are correct. In the PA rustbelt. I guess I'll just cut out the bad and fab something and weld it in. It looks like the original was spot welded on the outer flanges. Gotta love rust.

 

Not familiar with PA but I'd suggest talking to an inspection station first if your thinking of fabricating your own parts. Make sure you don't put a lot of time and work in to something that's going to be rejected.

EDIT: BTW, you need to be careful looking for parts online using places like OEM Ford Parts and Ford Parts Giant. I assume these places sell from Ford's parts inventory and\or buy Ford parts inventory when they no longer have to carry them because of age. There are dealerships that have their own databases of parts and have large inventories of NOS parts. You just have to look for them. There's a dealership around Boston I've gotten parts from where these other sites all said discontinued. It's a PITA but you just have to look. The dealership in Boston told me they build up inventories of soon to be discontinued parts because of the rustbelt thing. I've also had luck in areas like from Texas to California because they don't go through parts because of rust.

 

River1, I am going to just take it for inspection to a nearby garage now (thinking it will probably fail) and see what they recommend for repair. I believe 6 and 7 in the photo are what is rusted on mine. The parts are discontinued. No luck finding NOS either.

Thanks.

 

Check out the edit of my last post.

 

A quick look at used frames there are a number of rust free ones available for ~$550 from Texas. Considering how your frame looks that might be a way to go? You might even contact them about the crossmember and support only. You never know what they have laying around.

 

I can't see the frame in those two pics.... is it bad too?

 

I live in PA and mine failed several years ago for the same thing. The inspection station I use is pretty picky, but honest. I had a friend that did auto body for a living fix mine. He did what you said you want to do - He cut some metal and welded them in and then cavity wax.

 

River1: Thanks for the info on the dealer items. Makes sense what the Boston area dealer is doing. I know I've picked up a used front sub-frame for a 2005 Escape from a place in Arizona a few years back for a reasonable amount. The thing was basically new. No rust whatsoever. Night and day from what we see here. I plan to treat the frame this Spring with POR-15 or Chassis Saver.

Nameskreen: I think it's hit or miss with the stations in PA. I don't just want a sticker though. I want to make sure the thing is safe. My wife and daughter will be driving it as well. I'll see what they have to say when I take it in. Is your repair holding up fairly well?