Frame cracks?

[BadnewsBob]

Howdy Gents. While working on my truck to fix some other problems, I found some rust and bad cracks on the driver side frame rails, Just in front of the cab where it starts turning up.

I am getting ready to make some templates out of cardboard to make some frame plates, What thickness metal do you recommend for the plates?

I have 16 guage but I think that is to thin, I have a little bit of 1/8 but not enuff to do it all I don't think.

I am gonna do the passenger side as well while I am at it, Any thoughts?

[84Flatbed]

From what I've seen 3/16" seems to be what the over the counter frame plates are made from. Is that a common area for cracks? I know the front frame to crossmember is a common area, mine was cracked all the way around and mostly covered up by a home made steering box reinforcement. Of coarse the PO didn't tip me off to it I found it shortly after buying it.

[BadnewsBob]

I think it is a common spot, I started looking and found several different company's offering reinforcement for that spot, I bought some 3/16 plate, gonna cut some out tomorrow. and see what I can screw up.

[Slolyfe]

Did everything in ten gauge. Been holding up great.

http://board.marlincrawler.com/index.php?topic=84439.msg969059#msg969059

[84Flatbed]

Post some pics of the cracked areas and what you end up doing to fix them.

[jrock]

I vote 3/16", has worked great for me.

[OOPS]

I used .250 plate and ran it from the spring hanger to the body mount on all 4 sides, Also before I put the spring hanger on I ran a piece of 2x2x.125 wall square tube back on the frame rails about 6-8 inches. There is a lot of leverage on the spring hanger with big tires when flexing. The spring hanger has a tendency to crack at the front where it meets the frame rails. Overkill-yep!!

[BadnewsBob]

The rust and cracks.

[BadnewsBob]

The area to fix.

[OOPS]

You have some good rust problems there, plate all four sides of the rails.

[BadnewsBob]

Started the repair like this.

[BadnewsBob]

I got some 3/16 plate yesterday I am getting ready to make patterns and cut, I am gonna do all 4 sides and do both sides while I am at it. I will prolly add some extra reinforcement like you stated OOPS. Later I am gonna redo my shock mounts and take it all the way to the front.

This is an eastern truck rust like this is easy to find, it's the non-rusty ones that are hard to get.  Luckily It isn't rusted out bad just behind the cab. I think that is because it is a 2wd frame.

Hopefully my friend will let me use his rack......that will sure make it easier to weld.

[megaphoneman]

3/16 is over kill..

blahhhhhhhhhhh

[OOPS]

3/16 is over kill..

blahhhhhhhhhhh

I know that is why I used .250.

[Rockcrawlintoy]

Im with OOPS i used .250 and plated both sides. i also ran tube from the hanger along the frame like he did as well.

[megaphoneman]

Wait.. So 3/16 is over kill but 250 wall isn't?? 1/4 is way over kill...


Blaaaaaahhhhhhhhpppppppp

[BadnewsBob]

So far everything I've read, (Except for OOPS and Rockcrawlintoy) Have recommended 3/16th.  I am beating this on rocks, I don't want anymore cracks so 3/16th wins.

[Wainiha]

Overkill is better than doing the job twice.

[BadnewsBob]

Got one cut, Needs a little trimming and it'll work. I need more practice with the plasma cutter so I can make better cuts.

[BadnewsBob]

What do you think about cutting some holes in it to weld up also? I see it on a lot of doubler plates.

[BadnewsBob]

Im with OOPS i used .250 and plated both sides. i also ran tube from the hanger along the frame like he did as well.

What size tube? And did you just run it along the top then weld it down?

I'll prolly need to redo my shock mounts to do that.

I think I should have put this in my build thread.

[BadnewsBob]

I got them all basically cut, Just gotta clean them up some and final fit, It's raining and getting dark so welding them is a no go.

This fab work is hard on an old fat guy with a broke back, Sheesh! And I am slow at it.....

[Rockcrawlintoy]

What size tube? And did you just run it along the top then weld it down?

I'll prolly need to redo my shock mounts to do that.

I think I should have put this in my build thread.

I moved my box forward when i did it. I used 1 inch .250 wall dom for the bolts

[86bobbedtoy]

bob try using a straight edge when cutting with a plasma, amazing

[BadnewsBob]

I did problem with this cut was none of it is straight Most of it is curved.  I like when I can cut with a straight edge....That even makes me look kinda good.

I haven't cut much with it and most of that was thinner metal, 16 or 18 gauge is a piece if cake, I was having some trouble finding the right speed to cut the 3/16, But I'mma learning.

[megaphoneman]

Yes cut holes.. thats what i dont under stand.. ur using metal thicker then what the frame is.. if its not properly attched then it does no good.. no matter how thick it is...it will still flex and pull from crappy frame.. we do this stuff all the time.. and normally metal just as thick as the metal that the frame is works great and is strong.. esp if you rosset it correctly and in good spots... but hey... what do i know..

blahhhhhhhhhhh

[megaphoneman]

It should look like this...

blahhhhhhhhhhh

[84Flatbed]

I dont fabricate or weld although I wish I had the know how but the fabricator I've taken my truck to has told me that he doesn't believe that thicker material is always needed to make something stronger, he said something along the lines of rather than adding all the extra mass its more important to triangulate or disperse the forces. This is coming from a pretty well respected fabricator with a lot of experience in the off road industry. So, I guess my understanding is that its not the thickness of the material that maters as much as how its applied.

Maybe similar to what megaphoneman is saying.

[megaphoneman]

I dont fabricate or weld although I wish I had the know how but the fabricator I've taken my truck to has told me that he doesn't believe that thicker material is always needed to make something stronger, he said something along the lines of rather than adding all the extra mass its more important to triangulate or disperse the forces. This is coming from a pretty well respected fabricator with a lot of experience in the off road industry. So, I guess my understanding is that its not the thickness of the material that maters as much as how its applied.

Maybe similar to what megaphoneman is saying.

exactly!!

blahhhhhhhhhhh

[BadnewsBob]

I don't know. That is for sure, But I looked around and everything I found said 3/16, Except megaphone man, So that is what I bought. It remains to be seen.

I don't ignore or discard any info or criticism, I am a self trained amateur at best. That is why I am here, To ask and learn. So I won't mind when you make fun of my welds.

One other thing I am addressing and don't know if it makes a difference or not.....I am basically replacing the bottom of the frame due to rust.....So would you use like 16 guage or 1/8th?   Like I said I don't know and already had the 3/16th ordered.



Now for your viewing pleasure........ A selfie of the Fat Moron that works on my truck.