I want to do the travel mod to my tahoe but, I don't have a plasma cutter or a way to get one. Has anyone tried a saw-saw, cut off wheel, even a torch. Any suggestions guys are greatly appreciated.
I did it my self with a saw zaw and an angle grinder. i had a cutting torch but end up being a bigger pain in the ass. I used the angle grinder with a cutting wheel to cut the bumpstop bracket just below the weld on the outside of the frame. (be careful no to cut into the frame!!) Then i cut the outside of the that bracket off so there is access to the back of that bracket from the fron(or outside of frame). i did this so i could come at a 20-30 degree angle and cut the back side with a saw zaw. it is extremely tight if you dont completely drop the rear axel out of the vehicle. the angle grainder is essentail if you dont want it to look hacked up. you will also need to get creative around the front drivers side as the gas tank is right there.
In that area i use the cutting wheel to cut small pieces off, then came back with a flap Disc. you could can make it almost perfect if you have some pneumatic grinders and cutters.
End result was pretty good. looks clean and as if nothing was there. took majority of the day and im not new to the fab scene. you wil also need to get the axle mount bump stop. with a 4" drop you will have contact over large bumps.
there is a Sticky on this topic if you search it that has some pictures. well worth it though.
