Probably the most intimidating part of the build so far. Like every other part of this build I started to do my research and figure out my starting point. “How do I build a custom frame” or do I start with something existing and try to make that work. S10 frame swaps are super popular but I see a lot of pitfall and a lot of rework to make those frames work. I found the link below which is about building a rat rod on an extremely low budget. In the article he goes over all the basics of building your own custom frame. Well that looks easy… WCGW?
So I figured for a couple hundred bucks and some time I could at least try and see what I come up with. So I ordered my Steel and got to hacking away. This is how I did it, this is probably the worst way you can go about doing it. Please don’t take anything on this page as the “Right way”.
First think I did was measure the length of the cab, I laid out some marks on the floor beside the cab to represent the extreme back of the cab. The cab has a slight curve along the back to it was easiest to transfer that on the floor so I could get a accurate idea of the length to the fire wall.
I wanted to build a double Z frame which is just stepping up the frame in the front and the back to drop the cab lower. I wanted to hide the front Z on the interior of the cab… So I decide to follow the angle of the old fire wall. This way my front Z would be hidden from view and give the truck what I thought would be a cleaner look.
So now I knew my measurements the cab area needed to be 46″ long the Z was a 36 degree angle up and the motor needed at least 40″ of frame to use the original hood and grill. This is a bit long but I can trim it off later. Now the cab section of the frame had to support the rear step up as well so I had to add 4 inches to the measurement.
Just tack welding the parts together for now. I can go back later and really burn them in and finalize the welds. I will probably have someone else finish the welds on the frame as I am really new to welding and probably not the best part to learn on.
Added the start of the rear kick up as well. These ended up being 12 inches. I sorta guessed that the height I wanted them and figured I could trim them down later if I didn’t like it. So after I had both sides complete. I laid out both sides on jack stands and leveled and squared them up. I then measured the firewall on the front of the cab to figure out the max width I could get through that space. Turns out that was 29.5 Inches. So I cut 2 temp 1×1 steel braces at 25.5 inches long. Once I Was happy with the level and squareness of the frame I tacked those into place. These will come out later when the rest of the frame goes on and the front Axle cross member arrives.
Next I wanted to see if my measurements were correct so I had to get the cab on to the frame. So my lovely wife gave me a hand and we wrestled the cab up on to the frame.
Cab fit and the front Z fell exactly where I wanted it. Now I wanted to test the hood and grill.
So the Original grill mounts are too high so the whole hood sit way up. Not a good look. What if I mount it from the bottom of the frame?
That looks better but the grill hangs down far too low but that will be another days problem. The other thing I learned was the grill mounts narrow in at the front of the frame. Down to 26.5 so I know I have to narrow the frame at some point.
So now I need to know how much frame to build on the rear of the truck so I had to figure out the wheel base. More measuring more staring… more beers drank.
I settled on roughly 96″ for the wheel base… why? cause it looked cool. So now I was able to figure out how much frame I would need on the rear of the truck. Turns out to be 48 inches. I decided to build this part on the floor and mount it to the existing frame. As I just welded together a 48×29.5″ box. Tack welded again as I know I will make changes as I go.
With the rear portion of the frame welded on I wanted to make sure everything was square and level still.
Nope!! the back part of the frame had a slight twist in it. the back passenger side was down 1/4 of an inch. I welded this part on the floor so my floors must be a bit outta whack. No biggie I cut my tack welds and got it all leveled out and welded back together.
So now I have a semi complete frame that is level and square, it fits my cab and wheel base. From this point I can start thinking about the axles and suspension. I will come back and finalize the frame once I know every thing will fit.