Rust Buster RB7522L & RB7522R Over-Axle Frame Section Installation Guide

Required Tools

• Jack Stands or Lift
• Mig Welder
• Paint/Primer
• Hand Grinder
• Cutting Wheel or Torch
• Welding Gloves
• Welding Hood/Shield
• Ear & Eye Protection
• Sockets & Wrench
• Fire Extinguisher
• Paint Marker or Chalk
• C-Clamps
• Mallet

Kit Contains

• Over-Axle Frame Section (QTY: 1)

Installation Instructions

1) Preparing Your Vehicle

Begin by disconnecting your vehicle's battery before starting the installation.

Inspect your vehicle for any leaking fuel lines, fuel tank, or engine components. Repair all leaks before proceeding. If your fuel tank is located near the welding area, remove it prior to welding.

Remove all combustible items from the work area, such as seats, carpets, and padding.

Ensure all flammable materials are kept away from the vehicle work area.

2) Preparing Your Workstation

Keep a fire extinguisher readily accessible. Ensure you have a designated "Fire Watch" person to assist during cutting or welding phases.

Adhere to all professional welding safety standards and practices.

Always use appropriate welding eye protection, ear protection, and work/fire safety gloves during the installation and within the work area.

⚠️ [Warning] If you are unsure how to perform the installation or operate any of the required tools, it is highly advised to enlist the services of a certified welder/installer. Failure to follow proper safety precautions and instructions may result in serious injury. The user assumes all liability when installing the product.

3) Preparing for Your Install

Lift up or remove your vehicle's bed and remove the bump stop.

4) Cut

Position the new frame section against the vehicle frame and mark its coverage area. Draw a line approximately ½ inch above the bottom of the frame, tracing around the existing brackets. Cut along this line.

Note: Be sure to save both the original bump stop bracket and the fuel tank bracket. These will need to be welded back on after the new frame section is installed. If these brackets are damaged and need replacement, new ones are not included with this kit.

Grind the vehicle frame area clean of rust and debris, exposing bare metal.

Spray the prepared work area with a weld-through primer to help prevent future rust development.

5) Weld

Slide the new over-axle frame section into position on the vehicle frame, using the pre-drilled holes for alignment. Gently tap it into place using a hammer if necessary.

[Image Description: A vehicle frame section is shown being positioned for installation.]

If you intend to keep your vehicle's inner body mount, hold the new frame section in place and mark the location of your mount. Then, cut out the corresponding perforation on the new section. If you are replacing the mount, cut off the original mount and any other obstructions in the work area.

[Image Description: C-clamps are used to secure the frame section for a tight fit.]

6) Tack Weld and Full Weld

Following proper welding procedures, tack weld the over-axle frame section to the vehicle frame before proceeding to full welding. Weld 100% around all edges once tack welds are complete.

[Image Description: Welding is performed on the frame section, securing it to the vehicle frame.]

7) Reinstall Brackets

If you are reusing your original bump stop and fuel tank brackets: Take the bottom section of the frame rail that was cut off in step 4 and carefully cut out these brackets.

Measure the position of the fuel tank bracket on the opposite side of the vehicle to ensure proper alignment. Once measurements are taken, position the fuel tank bracket against the new frame section.

Position the bump stop bracket beneath the frame section, aligning it with the oval hole. Tack weld it into place.

Tack weld both brackets into their positions before proceeding to fully weld them.

[Image Description: Brackets are being tack welded into place on the frame section.]

8) Reinstall Inner Body Mount (If Applicable)

If you removed your vehicle's inner body mount, refer to the installation videos available on the Rust Buster YouTube channel for reinstallation guidance. This may involve part RB7521 - Inner Body Mount.

9) Paint

Paint the newly installed part with primer or another rust inhibitor to help prevent or reduce the risk of future rust formation.

Rust Buster recommends using their Rust Converter & Primer Spray Paint (RB9917).

[Image Description: A person is spraying primer onto the installed frame section.]

10) Final Reinstallation

Reinstall your vehicle's bump stop and bed.