The Total Cost Involved front suspension comes with frame boxing plates that need to be welded in. Its important that these plates are parallel to the surfaces and square to each other since the rest of the suspension welds to them.
The surfaces of the passenger side frame rails were pitted and wavy so it took a little extra massaging and grinding to get the reinforcement plates to sit where they need to be. The top edge of the side piece and the outer edge of the top piece need to be parallel. I also used a cut-off and sanding disc to get the top outer corner nice and straight.
It took a few clamps to keep the edges lined up for welding. The edges are supposed to parallel while leaving a small gap so you can include the old frame rail in the weld but my rail was a little too narrow.
I tack welded around the edges on all sides and left room to drill holes in the top outer edge to reveal some of the old frame rail. This allows me tie the old metal to the plates for extra strength.
These plates are completely welded but there is still one more plate to weld in on the bottom then a little more trimming.
Then its time to move on to the drivers side.