steerin box to frame carnage

[BoondocK5]

I guess I'm the only asshole who welded his brace all the way around...

Nope I had mine welded all the way around it. In fact, it was done with a stick type Arc welder, and 6011 rod. That thing is never coming apart.

 

[K5 Jess]

Yes I did if you look at the finished picture you can see the plates edge
PS. all that crappy welding was a repair from the previous owner. I had to grind it all off ,groove the cracks and re-weld them before even adding the weld on plate

Now that you point it out I see it!

 

[Slapperbar]

Nope I had mine welded all the way around it. In fact, it was done with a stick type Arc welder, and 6011 rod. That thing is never coming apart.

6011!!! You didn't even need to clean the frame with that junk rod! I assume you did and there is nothing wrong with it.

 

[Slapperbar]

it can cause stress risers in the frame...

As an Inspector I really want to know how. Stitched will allow some "flex" and a complete fillet will not.
Frame flex in that area is what causes the original problem.