Footbox AL fit question

[Avalanche325]

I have my passenger footbox mocked up. The inner panel is hard up against the 4" main tube to the point where I had to force it in. The panel buckels a little. Should it be that tight? Or does it need to be trimmed? If so, touching or just clearanced?

Thanks!

[MPTech]

Where is it against the main tube? If it's at the front of the FB, you may have header clearance (are you running shorties or 4-into-4's?)
If it's at the back, I'd trim it until it doesn't buckle.

[Avalanche325]

Front of the footbox. There is a cutout to go around the main tube on the inner panel in the drop section where you see the main tube from inside. The buckle is very slight. Just enough where it will pop in if you push it with your finger. I am sure it will not cause a header clearance problem, it is just maybe 1/4 of an inch. 4 into 4s by the way. I have seen things that vibrate while in contact act like a saw. I know the AL should give before the steel, but I don't want to create a stress riser in a frame rail.

I am thinking I will just ease it a bit.

[MPTech]

Is this the original FFR footbox or the expanded mod? (I'm not clear, you said front of the footbox, but you said where it goes over the main tube)
I'm talking about the front corner. If the front corner is touching the main tube, you will have header clearance issues. You may have to redesign it.

http://i9.photobucket.com/albums/a78/MPTech/P5060001-1.jpg

If it's the back of the footbox, off of the tranny horse-shoe, I'd clearance it so it doesn't buckle. Mark it and trim it with a dremmel.