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I don't know why the frame members alignment seems to fluctuate from one truck to another. I would "assume" that all holes where drilled in a "jig" of some sort thus making sure all pieces where the same. Maybe it has to do with multiple manufactures making the same truck, who knows ? One thing...
When I have used other frame members or pieces from other trucks they never align up exactly. So I usually try to fit as many bolts as possible then enlarge the holes that won't fit. This way it still is pretty secure.
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