Frame Crack - Repair Suggestions

[ZombieK5]

Found a small frame crack in the area of the passenger side shock mount location. This area was previously repaired and I'm assuming this crack is new (at least happened after previous repair). It's small, maybe 1" total.

This area has a steel plate welded to the top of the frame and a larger crack was apparently repaired already.

Plan is to drill hole at end of crack
Cut crack open to enlarge it with a V cut
Weld crack with setting for full penetration
Grind flat, or leave full weld
Paint

Thoughts or suggestions?

 

[ZombieK5]

Cleaned the back side and found more of the crack and more "previous owner" fixes. The welded washer was put in place to cover a major blowout for the original mount hole.

I may cut out the "washer fix", cut the hole to better fit another washer and clean up the repair. This would allow me to weld in a flat plate also.

I want to also grind down the heavy weld bead along the top of the frame then weld in a plate.

Ideas???

 

[ryoken]

sure.. my thought.. make precise measurements to locate the hole.. like points 6"s away..


than hog off the washer to orig rail... stop drill the crack, V, and burn in... smooth... bore an even hole with a fat step drill.. fit slug/patch.. burn in.. grind... locate hole center/drill.. if you want to spot a washer in after, have at it IMO...

is that a steering box hole?

 

[ZombieK5]

sure.. my thought.. make precise measurements to locate the hole.. like points 6"s away..


than hog off the washer to orig rail... stop drill the crack, V, and burn in... smooth... bore an even hole with a fat step drill.. fit slug/patch.. burn in.. grind... locate hole center/drill.. if you want to spot a washer in after, have at it IMO...

is that a steering box hole?

WOW...

No, it is the passenger rear shock mount hole. So to cover your suggestion:

1. Make marks so I can RE ESTABLISH the location of the existing hole
2. Not sure what "hog off the washer to orig rail..." means...
3. Drill and V-cut the existing cracks and run a bead
4. Step Drill to make larger hole where the existing washer and hole is located - FIT slug patch - Weld and grind smooth
5. Using earlier measurements, Drill NEW hole
6. Possibly weld another washer in place - could be used for added strength

Sound correct?

 

[ryoken]

pretty much.. hog off is me being funnay for, grinder + chisel/air hammer+grinder, etc to get to clean orig cracked rail.. stop, V, melt...

grind smooth before step drilling..


there are obviously easier methods that would prolly outlive you, leaving the washer..... but, you asked, sooooooo.

I'd prolly sandblast the chit too...

 

[ZombieK5]

pretty much.. hog off is me being funnay for, grinder + chisel/air hammer+grinder, etc to get to clean orig cracked rail.. stop, V, melt...

grind smooth before step drilling..


there are obviously easier methods that would prolly outlive you, leaving the washer..... but, you asked, sooooooo.

I'd prolly sandblast the chit too...

Thx for the "hog off" explaination!

I'm sandblasting the whole frame...

 

[ryoken]

I hope this is all getting an epoxy douche in the end...

 

[ZombieK5]

I just drilled and V cut the cracks and fixed some of the porous welds... Should work fine. Turned heat and wire speed up a bit, solid penetration...

 

[BlackHog Blazerr]

Thanks for the info, and nice work .