Steering box frame repair on a budget

[JK5]

I did repair on a buddies rig over the weekend, I thought I'd share some pics. I'm sure you've seen many repair jobs utilizing the ORD patch panel, on this post I'll show how to save a couple bucks. Here's the tools you need to get started, notice how the hammer or sledge isn't on the list. (Keep it in your tool box)

Hand grinder
MIG
Torches
1/2" impact
Hand Drill, 1/2"-9/16" drills

First, find a frame section with a healthy steering box area. Cut and clean steering box section, prepare it for welding.
(Find a 1 ton frame section, they're thicker)

Notice how I added 9/16" holes for plug welding.

Next, repair frame rail, weld any cracks. Then grind them flush, so the new frame section fits well.

Now, bolt the new section to the old section, don't worry if there's a huge gap between the 2 sections.

By adding heat to each corner, and hitting the bolts with an 1/2" impact, you'll notice the the patch will fit perfectly over the exhisting frame section.
Do that until you get a flush fit.

Weld around the outside of the patch, then plug weld the 9/16" holes.

After welding, cooling, you are now ready for steering box install.

 

[Chaddy]

Good job. Why didnt you use the bottom patch plate?

 

[JK5]

Good job. Why didnt you use the bottom patch plate?

Thanks, bottom patch plate, please explain....

 

[Chaddy]

Thanks, bottom patch plate, please explain....

This 1.

 

[JK5]

This 1.

I guess I could have added a plate top and bottom of the rail, this rig is getting hydro assist, they're not needed.

 

[slyguy_22]

yeah u did a nice job on it but it seems to me that without doing the bottom that will be a weak point.

 

[JK5]

yeah u did a nice job on it but it seems to me that without doing the bottom that will be a weak point.

I've done a couple frames like this, they're fine. With the steering box bracket kit from ORD and hydro assist, this repair will work. Notice how the welds are on the bends of the frame rail? That's where strength is needed.

If you're not using hydro, I would definately add to the bottom of the rail.

 

[Chaddy]

If its not full hydro, I would slap that bottom plate on there just to be safe.
There will still be quite a bit of force on the frame with just an assist ram.

 

[slyguy_22]

Yeah didnt realize you were using hydro. without hydro they usually tear at the bottom on the inside too

 

[JK5]

If its not full hydro, I would slap that bottom plate on there just to be safe.
There will still be quite a bit of force on the frame with just an assist ram.

On my buggy, I have a stock frame, no patch panel, ORD support, hydro-assist, 44"s...It's not babied either. I have no issues with the frame...

I may add a plate to the bottom, just to be safe.
Making that plate, is a piece of cake...

 

[dieselponyexpress]

Installation sheet of the ORD unit says not to weld all around iirc. I'm no welding expert by all means, just replying what i read years ago when doing my frame repair.
Or is it just the pic that makes the gaps hard to see?

Walter

 

[tRustyK5]

Welding it solid like that will eventually cause problems. If you look at the ORD repair plate it's shaped and has a very specific stitch pattern to prevent the frame from cracking next to the big vertical weld...

I'm not saying you can't make you're own repair 'kit', just that there is more to it than just doubling the area and welding the crap out of it.

Rene

 

[Mudstud]

Since we're talkin budget repair/beef. . . I put the frame patch kit on when installing the lift. Several years later I boxed the frame up front in a few spots including the back two bolts for the steering box. They are sleeved too. I left the front two bolts alone as I wanted to have access to that area of the frame should I decide to do a front spring swap. The metal is over lapped cuz it's all I had to do the job. Also patched a crack that had developed on the pass side of the engine croos member.

 

[JK5]

I was going to weld a plate on the bottom, but the owner of the vehicle was happy with the repair. His problem was, the mounting holes pulled thru the frame. We'll keep an eye on it, because he's pretty hard on the rig.

On the trail, I haven't seen one of my welded frame rails snap off, but I have seen tie-rods and steering box output shafts break off. Sure welding the frame solid may not be the best repair, but it seems to work well on the trail, for what we need.

My frame is stock and has no issues...I think it has to do with driving styles. When I'm against a rock that isn't going anywhere, I don't put all my might into turning the wheel. I find a better line...