American Expedition Vehicles Brute Frame - Manual (Page 7)

Page 7 of 20
9. Drill and tap the extension jig mounting holes. With the cutting jig still firmly clamped in
place, use a 3/16” pilot bit and carefully locate the tip in the center punch mark and drill.
Step up to a 1/4” bit next and finally your R Bit (21/64)(8.5mm). Take the self tapping bolts
supplied in the Brute hardware Pack and carefully run them into the holes with an impact
wrench. DO NOT TIGHTEN; the point of this step is to thread the holes. Repeat the
procedure for the opposite frame rail.
10. Cut the frame in half. Remove the cutting jig and using the combination square, transfer the
scribe line around the frame. Support either side of the frame with jack stands and carefully
cut along the line. Use a Sawzall, plasma torch or gas torch. We use a Sawzall because it
does the cleanest job.
11. Prep the frame ends for welding. Carefully clean all slag or burs from inside the frame rails
with a file or die grinder. Using the four inch angle grinder bevel the edges of the frame rails
with a 45 degree angle.