Re: installing a front crossmember
To add to what everyone else has said;
As Bob said, the holes must be ¼". If someone has drilled the rivets out to install bolts, the hole will need to be welded closed, then redrilled with a ¹⁵⁄₆₄ drill and reamed to ¼".
Next, an air hammer will not set a rivet. It must be a rivet gun. We use a 3X rivet gun.
Use the smallest torch tip or an induction heater to concentrate the heat to the rivet instead of surrounding structural metal. Heating the surrounding metal only expands that metal too and you do not get a strong compression in the hole.
Make sure you measure the crossmember location using triangulation. Check that the frame is square prior to measuring the crossmember.
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