So both of these areas are non-structural, but, if you really want to get anal about it, you could do the following:Am I the only one who feels like this sort of trimming will both affect crash safety, and possibly cause the force exerted by the drivetrain to either warp the frame or damage the front diff in some way. From my experience with the RS, you want to bolster the mounts holding the various diffs/drivetrain pieces in place, not trim them back. It's a common issue for RS's with performance tunes to produce enough torque to actually twist the PTU (center diff) and destroy it, quite dramatically. One of the popular mods from Mountune is for reinforcing that mount:
https://www.mountuneusa.com/Focus-Rs-Ptu-Brace-Upgrade-p/2536-pbkt-aa.htm
The difference between the stock mount, and upgraded ones are massive -- I worry that trimming the Bronco's frame around the front diff will dramatically weaken its support as well. These parts of the install instructions worry me:
1. After removing the frame extensions you could either make a 1/4" thick plate to slide in and attach with 4 bolts. Alternatively, should you not wish to bolt a cover plate, you can weld a plate in place rather easily to box it closed.
2. After cutting the front diff mounts flush you could pin it in place for the purpose of keeping the location accurate. Alternatively, you could even weld that area if you want to really make sure that it will never move, but I think that a pin for locating it is a better option. As the function of the tabs is for location.
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