Frame repair

[Slolyfe]

Well 5 days before the round-up I discovered my frame was cracked right in front of my steering box. It was torn 3/4 the way around right where it meets the front cross-member. Upon closer inspection i also discovered 3 more cracks by the motor mount, shock hoop, and one running 8 inches of length of the frame.

So a new truck is in my future but need this one to last me a few more trips so here is the damage and repair(I didn't see a thread on this). So please give me some tips I'm new to most of this.

Yes some of the old welds are ugly but they are gone now.

[Slolyfe]

Some of the patchwork. It is all 10 gauge.

[pumkin toy]

looks like you are geting it figured out.  the most important thing you want to dowhen welding up cracks is to get a grinding wheel and gouge out the crack for its entire length plus i little bit past on each end.  this will clean out any dirt and grease thats inside the crack and it will also give you a larger surface to fill in with weld.  just make sure your welds penetrate nice and deep into the crack so you dont sand it all off before you put a plate over it.  Sometimes a plate isnt needed if you just have a small crack somewhere, but obviously you have quite a few issues so plates are a good idea!

[Slolyfe]

Thanks, i drilled a hole at the end of each crack to keep it from spreading then ran a cut-off wheel up the cracks. It sucks cause most these areas are so tight i have to use a dremel.

[pumkin toy]

yeah drilling a hole will help stop the crack too, sounds like you did everything right!

[floorrunner]

try not to weld continuous beads, as if a crack starts it will go the length of the weld. weld in 2 inch sections. also u can never over plate an area. bare metal is key to strong welds. use high heat and burn em in.

[Slolyfe]

Thanks for the advice guys. Some more progress today, Gotta finish it by tomorrow night cause we are headed to the round up! Should be fine though.

[redrocket93]

Nice work on the frame repair. What's this new truck you speak of? See you at the Round up.

[Slolyfe]

Well, this truck is showing its age so I would like to start a new build. Just no time or money, we will see how she holds up these next few trips. But she is all back together and on the trailer.

[fordh8r]

  looks good, Bro! Rock it! 

[santa cruz crawler]

Nice welds !

[Slolyfe]

Nice welds !

Thanks it was defiantly a learning experience. All of it was covered in power steering fluid(which I burnt out with the torch and wire wheels) and very tight spaces. So a lot of the welding was one handed and blind. It sucked but was a good learning experience. Now I just hope it holds. Hahaha

[Wermz84]

Glad I saw this thread. good tips on frame repair.  Glad you got it done in time.  I'll have to sneak a peek at it when we are up there.

[TURBO]

hey good idea with this gusset...

i assume this was originally a solid axle truck? ... I have seen a few of these frames crack in this general area... solid axle trucks had a push pull steering box, and when you convert to an IFS steering box, all the stresses change... not only is it trying to spread the frame, it's also twisting it...

only other suggestion i can bring up is an additional cross member, from one side to the other, this will help stop the twisting and spreading loads on the frame...

idk something to incorporate into your new truck when you get there...

[Slolyfe]

hey good idea with this gusset...

i assume this was originally a solid axle truck? ... I have seen a few of these frames crack in this general area... solid axle trucks had a push pull steering box, and when you convert to an IFS steering box, all the stresses change... not only is it trying to spread the frame, it's also twisting it...

only other suggestion i can bring up is an additional cross member, from one side to the other, this will help stop the twisting and spreading loads on the frame...

idk something to incorporate into your new truck when you get there...

Yea it is an '82 frame. I added the sas front hanger. I may add one more gusset above this one. Another cross member would be nice but there is a lot going on under there with the cross-over and hydro-assist.

I just got back from the Round-up and it held great. So now just time to keep an eye on it.

[Wermz84]

Glad to hear it held up,  guess now it's time for that Hendrix chassis. 

[superyota]

........
I just got back from the Round-up and it held great. So now just time to keep an eye on it.

looks good.  now get your windshield back in.  just kidding

[Wermz84]

looks good.  now get your windshield back in.  just kidding

   But he likes it when the wipers hit him in the face when he accidentally hits the switch.

[superyota]

   But he likes it when the wipers hit him in the face when he accidentally hits the switch.

yea, he showed me wiper trick when I asked him about the windshield at the springs

[Slolyfe]

I actually like not having a windshield now. Keeps you cool and there is never a glare! Good seeing you guys this weekend!

[Wermz84]

Good seeing you too.  

[fordh8r]

Found this on Pirate! 

http://www.moranton.com/gallery/marlin_091711/content/0138_marlin_roundup_091711_large.html

[Slolyfe]

Nice! Thanks!

[Wermz84]

Nice.