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    Preferred Solder for Automotive Wiring

    What wp29p4a said. Thomas & Betts STA-KON model WT111M has been my go-to crimp tool for 40+ years. Uninsulated butt connectors and ring terminals (don't cheap-out, buy good quality brand, brazed-seam if you can find them) followed by waterproof heat shrink tubing (has heat-activated glue/sealant...
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    Headlight switch keeps getting ruined.

    as Radiohead points out, high resistance at a plug terminal will create heat and cause subsequent heat damage to switch internals... My first thought was headlight bulbs have been replaced w/ higher output, higher current devices...this may increase current draw in excess of the rated current...
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    Rear Cross Sill help!

    If all else fails, try googling "hat channel". Its an industrial building product. Might get lucky if what you need is a standard hat channel dimension. 16ga. mild steel would probably work nicely. Hat channel + square tube stack a possibility too.
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    Rear Cross Sill help!

    Was looking thru AMD's catalog and noticed they offer the rear cross sill; https://www.autometaldirect.com/body-components-cross-sills-rear-tail-pan-cross-rail-assembly-complete-73-86-chevy-gmc-ck-fleetside-pickup-87-91-chevy-gmc-rv-fleetside-pickup-w-steel-bed-floor-p-1343.html Near as I can...

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