Want to install aftermarket intrusion beams but don't want to/can't cut the old ones out? I did it!

[Glocker]

This thread may make some people cringe, but I promise, it wasn't bad at all. ?

I don't know if this is better here in the Tires/Wheels/Brakes section or if it would be better in the suspension section, but here you go:

I originally attacked the stock driver side intrusion beam with my reciprocating saw and it chewed up the blade and only just scratched the beam. This wasn't going to work and you need to get the old beam out to install the aftermarket beams, so I hit the corner of the fender in the wheel opening with a hammer to bash it out of the way. Sounds terrible, but it was only a couple (maybe four to six) of quick hits, a spray of paint to prevent rust where the hammer knocked the paint off, and the fender trim covers it all. The aftermarket beams I installed (BDS Suspension) then slide in easily due to their shape.

This is where the body panel interferes with removing the stock intrusion beam.

This was after four quick raps with the hammer. It gives you just enough to slide the stock intrusion beam out.

After applying a little paint to prevent rusting, and getting it all buttoned up back together, you can't see what I did at all. You can see where the black paint over sprayed quiet a bit, but I didn't wipe this section off before painting it so I'm anticipating this paint will come off.

BEFORE:

AFTER:

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[DukeCanBuildit]

Good job John - PITA, I know, but worth all the tears and cursing when it’s finished.

 

[mtsoxfan]

Maybe its the lighting, but it looks like red primer everywhere...

 

[NotBudule]

What size are you going with now that those are gone ? Is it just the rear ones in the way or front ones also ?

 

[RedDakooter05]

Maybe a dumb question, I've seen lots of people cut or otherwise damage body panels to get these things out... Is there a reason nobody is unbolting the body from the frame and just lifting it to clear the bars?

Like pull the bolts, use block of wood and just floor jack it up a couple inches.

 

[Glocker]

Maybe a dumb question, I've seen lots of people cut or otherwise damage body panels to get these things out... Is there a reason nobody is unbolting the body from the frame and just lifting it to clear the bars?

Like pull the bolts, use block of wood and just floor jack it up a couple inches.

I think the amount of time that would take would be prohibitive. I think an easier route would be to take the fender off, but that would still take a huge amount of time.

 

[Glocker]

What size are you going with now that those are gone ? Is it just the rear ones in the way or front ones also ?

The fonts went away with my front bumper a couple years ago.

 

[Glocker]

Maybe its the lighting, but it looks like red primer everywhere...

Probably old Georgia clay.

 

[RedDakooter05]

I think the amount of time that would take would be prohibitive. I think an easier route would be to take the fender off, but that would still take a huge amount of time.

2 bolts per side, shouldn't be overly difficult to remove. Especially with an impact gun.




... Kinda want to try this now to prove a point but I don't really have a need to do such a thing.

 

[Bob902]

2 bolts per side, shouldn't be overly difficult to remove. Especially with an impact gun.




... Kinda want to try this now to prove a point but I don't really have a need to do such a thing.

Do It!!!!!

 

[RedDakooter05]

Do It!!!!!

Will get back to you on that when my garage isn't full of water/snow.

 

[gwhalin]

I was able to remove the rear beams on mine without cutting or altering the panel. I was able to just pull them out. I got them as far as they would go and then grabbed with some plyers pulled at an angle and they slid right out. Guessing tolerances are not consistent on everyone's truck.

 

[NotBudule]

The fonts went away with my front bumper a couple years ago.

You have enough metal up front to make another Ranger sir !

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