notching crossmember

[in2fords]

Im slapping in a 435/205 and now am at the point of making a crossmember. The metal shop in town gave me a good deal on some 2.5 square with 3/16ths wall so thats what im using for now.
I need to notch some for the front shaft and would like to know how much I can safely notch out if I replate the cutout? Im hoping 1-1.5" wouldnt be to much.
heres a pic of 1.5 marked out.


Thanx, Jeremy

 

[vetteboy]

Is this just supporting the transmission, or are you mounting links to it as well?

 

[in2fords]

Just transmission/transfer. Once I get to wheel this thing for about a year, I plan on making a new crossmember so I can run links/skid whatever. I know the tube is over kill but it cost less then half then the sticks I wanted and money is TIGHT right now.
I was planning on cutting it and bringing it around the front output but that doesnt seem possible without losing ALL ground clerance.
I have a plazma and a lincoln sp-125 mig and a buddy who has a 220v stick welder so i can fab it up. I just havent done it before so dont know what I can get away with safely.
Thanx, Jeremy

 

[in2fords]

I just went ahead and notched it. I figure it will be plenty stong, just wanted to check.
Jeremy

 

[Matt S.]

looking at the (approx) 16ga stock crossmember...

im sure that notching that material that small ammount will be pleanty strong...

 

[ZacSquatch]

I have a 2x4 1/4 wall.. notched it down to 3/4" and welded a 1/4" plate to the top of the remaining hole to get 1" and also 1" drop of the TC from stock.

 

[Skwerly]

Yea, I'd go for that, especially since it will be welded again, no problems there. In fact it's still probably thicker than anything stock LOL! Let us know how it turns out!

 

[in2fords]

The only real concern I had was that the stock setup had another mount on the side of the t-case. Im going with a different mount so maybe I dont need it. Only time will tell.
Thanx, Jeremy