ok so i am in the middle of piecing my cummins conversion together on my extended cab 91. i just got every thing sandblasted and painted went to put the crosmember up in and one side will line up but the other is not even close its almost like the crosmember is to wide. the other problem is that the one side needs to come back more but it wont if i put the bolt in on the drivers side.
need help asap!

 

So give us some info on what pieces are being used in this conversion. Original gasser parts, or cummins 1st Gen parts, Frame from gas or diesel, tranny etc.

 

I can't be of too much help, but ran into similar issues putting a crossmember from a 1993 Diesel into a 1972 W200 Gasser. I needed to spread the frame rails slightly with the farm jack to get things to line up.

X2 More info needed.

 

You need an alignment punch: 12 Piece Industrial Punch and Chisel Set

Put the punch through the frame and or crossmember and twist, pull to line up the bolt holes.