Leaf spring hanger replacement

[doyouquaxu]

I have an 01 sitting with no rear suspension on it currently. It has the modular frame, so the rear portion of the frame is separate from the front and cab portion of the frame. They're joined with 8 rivets per side, 4 of which are the rivets holding the leaf spring hangers on. The problem is that I can not get the rivets out of the frame to put the new hangers on.

PB Blaster, big hammers, punches, grinding the rivets flat to the frame, and lots of curse words have not helped. The next thing I do is get the torch out unless someone has a better idea? I really don't wanna drop the tank to torch the drivers side ones.

This is what I'm dealing with, the 4 holes on the side of the frame is where the rivets are stuck on mine. Pic pulled off the web for reference:

 

[mcdonald58]

When I did this job the bolts on one side came out with grinding the heads flat than a couple of whacks with a hammer. My teacher had to take a torch to get the rivets out of the frame.

 

[doyouquaxu]

This is all rivets, none will budge. Heat and an air hammer were suggested by one person, but I don't have access to air tools where the truck is. Heat and a BFH might have to do, or drilling them out.

 

[Diablo]

if you drill , use a cobalt bit.

 

[Brinker88]

Weld the holes shut weld the frame together and use RuffStuffSpecialties frame outriggers.

http://www.ruffstuffspecialties.com/catalog/OUTRIG-45.html

I've ALWAYS used an air chisel to remove those rivets. I got mine at Lowes for $20. It's a Kobalt

 

[doyouquaxu]

Weld the holes shut weld the frame together and use RuffStuffSpecialties frame outriggers.

http://www.ruffstuffspecialties.com/catalog/OUTRIG-45.html

I've ALWAYS used an air chisel to remove those rivets. I got mine at Lowes for $20. It's a Kobalt

I have new hangers specifically for the spring pack that is going on the truck. The frame will be welded at the junction though

 

[cvar]

I used an ordinary HSS 3/8" drill bit to remove the rivets. After grinding off the rivet heads, make a dimple with a center punch, so the drill bit won't wander.
Then drill into the rivets about 1/2" deep. Lastly, use a hammer & punch to knock out the remainder of the rivets.
This works on even the toughest rivets. No heat needed.