69-72 front cross member/horse shoe bracket alignment problem

[Brad M.]

I am installing the front cross member and the front bumper horseshoe bracket on my 71 and seem to have an alignment problem.

I have mounted the front cross member. When I attempt to install the front horseshoe bracket to the cross member, it seems that the bracket would sit to high and too far back once all bolts were tightened.

Should there be shims or spacers used between the front cross member and the radiator support and/or frame? It seems the angle of the crossmember needs to changed such that the front of it is lower than it is currently.

I do not remember if there previously were any such shims or spacers, but it has been about five years since I removed it. I can not seem to find anything in the assembly manual which helps either (but I may be overlooking it)

Any help on this would be appreciated.

[Chuck S.]

Re: 69-72 front cross member/horse shoe bracket alignment problem

...I have mounted the front cross member. When I attempt to install the front horseshoe bracket to the cross member, it seems that the bracket would sit to high and too far back once all bolts were tightened.

Should there be shims or spacers used between the front cross member and the radiator support and/or frame? It seems the angle of the crossmember needs to changed such that the front of it is lower than it is currently...

No shims shown in my AIM.

There appears to be little tolerance at the front bumper brace or the rod brace; this assembly is designed so that it is what it is, and unless the frame has been damaged or the body not mounted properly, it should be fine. I suspect your front end could have sagged some if the very front was unsupported for five years...fiberglass front ends are not as strong as steel, and will sag with time.

If I recall correctly, the bumper brace holes at the cross member ends and the cross member to frame bolt holes are slightly elongated. My approach would be to not torque the cross member or the brace completely until the front bumper is mounted loosely with all its supports and the rod brace to the radiator support installed; then torque the two bolts at the bumper and then those at the cross member, and then the cross member bolts. Check for fit to make sure everything fits up as expected. Then fine tune the bumper alignment and torque the other bumper supports and brace rod.

If the front bumper brace remains too short, the body/frame or something hasn't gone back together like it came apart.

[Brad M.]

Re: 69-72 front cross member/horse shoe bracket alignment problem

Chuck,

Thanks for the thoughts. A couple items to note on my situation:
- I did not take off the body, so do not think that could be the cause

- I am not aware of any front end damage ever on the car

- it assembled about five years ago. The radiator support, cross member, and bumper horseshoe bracket were all removed. The radiator support and bumper horseshoe bracket are the originals to the car.

- I did replace the front cross member (due to a rust spot in my original). I originally thought the replacement was potentially bent out of shape, but acquired an additional one and have the same problem

- I definitely think there is some sag in the fiberglass which will need brought back up, but this is not the primary problem as there is way too much difference.

- your suggestion on method of installing seems like a very good idea, I will definitely try that (but I think there may still be more to the problem).

Thanks

[Chuck S.]

Re: 69-72 front cross member/horse shoe bracket alignment problem

...I did replace the front cross member (due to a rust spot in my original). I originally thought the replacement was potentially bent out of shape, but acquired an additional one and have the same problem

...I definitely think there is some sag in the fiberglass which will need brought back up, but this is not the primary problem as there is way too much difference...

The cross member shouldn't have any dimensional differences if it's a direct replacement. I don't know of any changes to that cross member over the years. The combined tolerance of all the slotted holes should be well beyond any reasonable thickness of shims, so shims were never required. If nothing else works, you can always try it with the old cross member if you still have it...that should at least help you to understand the difference.

I'm pretty sure that the front end sag will no longer be important once it has been re-supported. How much difference are we talking about between your nose fiberglass and the bumper brace? I wouldn't be surprised to see inches difference rather than fractions of inches. You'll find that the fiberglass will be relatively easy to deflect during initial travel, maybe an inch or less, but it gets very hard after that.

[Brad M.]

Re: 69-72 front cross member/horse shoe bracket alignment problem

Chuck,

I think your suggested installation method to tighten up the cross member after installing the horseshoe bracket and support rod will definitely help - thanks

Brad

[Chuck S.]

Re: 69-72 front cross member/horse shoe bracket alignment problem

As with any panel installation, apply masking tape to possible interference areas behind the bumper before installation. I wouldn't want you to blame me if that bumper flops around and chips your paint while it's "loosely" assembled.

[Kenny C.]

Re: 69-72 front cross member/horse shoe bracket alignment problem

Brad
I recently assembled my 69 after being apart for several years and I can tell you that these things were not exactly precision fit. I had similar issues and it took quite a bit of juggling and tweaking to get everything back in shape. Things started soooo far off that like you I assumed something must be really off. Fortunately I was working with a gentleman who has decades of experience restoring these cars and he encouraged me to keep playing until it all went together an frankly not to expect it to go together like a Swiss watch because it just isn't very well designed and just wont be perfect. Remember when these were built they were just a typical production car and not a historic monument so fit and perfection were not the motivation. Do what you can to make things fit nicely and at the end of the day you will likely have it better than it rolled off the line why back when.
Regards
Kenny

[Edward J.]

Re: 69-72 front cross member/horse shoe bracket alignment problem

Chuck, there are shims under my front bumper support , not radiator support. the will help with the bumper alignment. correct or not?