I’m not sure what the heck some previous owner did with my 66 Satellite but I had about a half dozen of those 1” holes in the bottom of the frame rails apparently used for trailer tie downs that were distorted - some pretty severely - both front and rear. At first I thought maybe it was damage from a frame machine but I’ve had this car pretty extensively disassembled, bumpers off, all interior out, scoped every where I couldn’t see, and I can’t find a wrinkle, replaced panel, repaired chassis floor panel or any damage anywhere underneath or in the main body structure. Just a small repair on a hood corner and ding in the trunk lid. I think they just tightened the hell out of trailer tie downs and/or the suspension action stretched the metal.
Anyway, the underside has been stripped and repainted somewhere in the past and still reasonably clean so all those distorted frame holes bugged me. I got a grade five bolt and a bunch of heavy/thick 1” washers and a heavy 1-1/2” washer. With 3 heavy 1” washers under the bolt head I fed it up through the hole, put the 1-1/2 washer on the outside of the frame and a couple more 1” washers behind it and the nut. Positioned the bolt towards the pulled area with the big washer on top of the pulled area, snugged it in place and rattled it down with an electric impact. It typically took around 3 or 4 separate bites at it but it flattened the metal back down to profile and even left the hole’s original round shape, although I did run a 3/4 inch stone in my drill up there to dress it up. On the front rails there are a couple oblong slots that allow slipping a larger washer inside with opposing edges ground down a little to match the interior frame width. It took a bunch of fishing around inside to get the bolt inside the bigger washer with a couple smaller ones on top but I managed. A little primer and lacquer touch up over the area and they look good as new.
Thought someone doing an under-car cleanup might run into the same thing and could use this.
Anyway, the underside has been stripped and repainted somewhere in the past and still reasonably clean so all those distorted frame holes bugged me. I got a grade five bolt and a bunch of heavy/thick 1” washers and a heavy 1-1/2” washer. With 3 heavy 1” washers under the bolt head I fed it up through the hole, put the 1-1/2 washer on the outside of the frame and a couple more 1” washers behind it and the nut. Positioned the bolt towards the pulled area with the big washer on top of the pulled area, snugged it in place and rattled it down with an electric impact. It typically took around 3 or 4 separate bites at it but it flattened the metal back down to profile and even left the hole’s original round shape, although I did run a 3/4 inch stone in my drill up there to dress it up. On the front rails there are a couple oblong slots that allow slipping a larger washer inside with opposing edges ground down a little to match the interior frame width. It took a bunch of fishing around inside to get the bolt inside the bigger washer with a couple smaller ones on top but I managed. A little primer and lacquer touch up over the area and they look good as new.
Thought someone doing an under-car cleanup might run into the same thing and could use this.