Post by Dr. Burkeee on Feb 27, 2007 1:24:15 GMT -4
This is a little off topic for the jeep board, but I thought I'd post up what I've been working on for the last little while. I figure rust and frame repair is a universal subject in NS 
A 92 Tracker that was bought at the auction, the owner took it for an inspection and the mech found a badly rotted front frame. Basically told the guy it was junk, not fixable.
Front body mounts were soft.
Front 10" of frame destroyed and the front crossmember (to which the suspensions mounts) was blowing in the wind.
I was really bad, but not unfixable. With what the owner paid for the truck, paying to have the frame fixed would still give him a good vehicle for the price.
I was able to find a solid front frame section from another tracker, so off came the rusty section. Measure twice, cut once. Then grind and check the fit, grind and check the fit X 1000 ;D It was much more work cutting the fishmouth notches, but they are much stronger and distribute the effect of the welding heat affected zone. The notches are different lengths on the inner and outer sides of the framerail to further distribute things.
Internal gussets where made for each side out of 1/8" plate. Some interesting shapes were necessary to clear the steering box mounting holes. Was tight to fit the mig in there but as much area was welded as possible.
Test fit before welding, connected steering and suspension to check that everything lines up.
Tacked in place and another test fit. Rosette welds to attach the other side of the frame to the gussets.
Root welds were done first to burn the edges of the frame to the gussets. Then a big fat cover bead overtop to give lots of material to gind down flush.
Ground flush to blend into original frame pieces.
Primed and painted.
Other side done exact same way.
Everything bolted back up perfectly, I'm glad I spent so much time fitting the new section.
Done! Now the body and lower control arms actually connect to something ;D
Paul
A 92 Tracker that was bought at the auction, the owner took it for an inspection and the mech found a badly rotted front frame. Basically told the guy it was junk, not fixable.
Front body mounts were soft.
Front 10" of frame destroyed and the front crossmember (to which the suspensions mounts) was blowing in the wind.
I was really bad, but not unfixable. With what the owner paid for the truck, paying to have the frame fixed would still give him a good vehicle for the price.
I was able to find a solid front frame section from another tracker, so off came the rusty section. Measure twice, cut once. Then grind and check the fit, grind and check the fit X 1000 ;D It was much more work cutting the fishmouth notches, but they are much stronger and distribute the effect of the welding heat affected zone. The notches are different lengths on the inner and outer sides of the framerail to further distribute things.
Internal gussets where made for each side out of 1/8" plate. Some interesting shapes were necessary to clear the steering box mounting holes. Was tight to fit the mig in there but as much area was welded as possible.
Test fit before welding, connected steering and suspension to check that everything lines up.
Tacked in place and another test fit. Rosette welds to attach the other side of the frame to the gussets.
Root welds were done first to burn the edges of the frame to the gussets. Then a big fat cover bead overtop to give lots of material to gind down flush.
Ground flush to blend into original frame pieces.
Primed and painted.
Other side done exact same way.
Everything bolted back up perfectly, I'm glad I spent so much time fitting the new section.
Done! Now the body and lower control arms actually connect to something ;D
Paul
