1980 Ford Bronco Frame Reinforcement Project Diagram - Plating, Foam & Cage Tie-In

This is a hand-drawn schematic (created in a paint program) illustrating a three-step frame reinforcement/repair project, uploaded as 'frame project' for a 1980 Ford Bronco. Step 1 shows two dark grey steel plates being welded (purple) inside the original black frame rail. Step 2 shows a larger steel plate welded along the open side of the frame rail, with a note that foam will be injected to completely fill the internal cavity. Step 3 shows the plated frame rail with a series of welds (purple dots) along its length. A detailed cross-section at lower left shows how a 2" stainless steel (SS) tube passes through the frame: it is secured with a grade 8 bolt head, washers, and nylock nuts, sealed with Permatex, with expanding foam filling the frame cavity; light grey tubing extends 'to cage' and 'to sliders' (rock sliders). A color legend explains the drawing: black = original frame, purple = welds, dark grey = steel plate, light grey = tubing, red = bolts and nuts. The document teaches how the builder plans to box and reinforce the frame, fill it with expanding foam, and attach roll cage and slider tubing through the frame using through-bolted sleeved connections.