Frame Repair

[Frankie]

Pics of the front frame of 22192. As you can see, there is welding needed on the front crossmember and the gussets are quite bent. Additionally, the frame horns are bent and the front spring hangers seem to be angled. In this case, would it be best to remove the gussets and spring hangers and install replacements after straightening the frame?

DSCN3884.JPG (114.57 KiB) Viewed 819 times

DSCN3904.JPG (101.77 KiB) Viewed 819 times

DSCN3885.JPG (184.23 KiB) Viewed 819 times

DSCN3887.JPG (105.03 KiB) Viewed 819 times

DSCN3893.JPG (103.28 KiB) Viewed 819 times

DSCN3895.JPG (129.15 KiB) Viewed 819 times

DSCN3901.JPG (120.43 KiB) Viewed 819 times

DSCN3902.JPG (135.62 KiB) Viewed 819 times

[Daren]

Hi Frank,
I had similar damage to the front frame horns on my gpw to the extent where I need to remove both horns as complete units. I found very good reproduction items which after lots of measuring I cut off the old and replace with new. However even after all the measuring I still managed to have one sitting lower so I had to recur and re weld so they stayed level with each other. This may have been because I did this work with the chassis in its individual pieces.
Good luck and measure lots cut once if you decide to go that route.

[dpcd67]

DSC00779.JPG (140.41 KiB) Viewed 793 times

I had my local sheet metal shop bend up some C channels and I welded them in.
How do you keep them level? With a level. On level ground.

[Daren]

Hi, I eventually sat the frame (chassis) on stands and made sure it was level, with a level and the as you have done fitted the bumper and leveled that, tack welded and rechecked, made adjustments and rechecked also checking the overall length and the diagonal dimensions, using specific locations for measurements.
Good luck.

[JIMN]

I would repair what you have. Maybe it is the photos, but it doesn't look too bad to me.

[YLG80]

I would repair what you have. Maybe it is the photos, but it doesn't look too bad to me.

I agree with JIMN. (except if you want to make a factory restoration.)
But the cracks needs definitely to be stopped by drilling a little hole.

DSCN3884.JPG (31.27 KiB) Viewed 674 times

DSCN3893.JPG (31.43 KiB) Viewed 674 times

DSCN3901.JPG (45.44 KiB) Viewed 674 times

DSCN3904.JPG (40.81 KiB) Viewed 674 times

Yves

[fiveftsix]

That`s all repairable, no need to cut anything off.
Front Cross member clean off all that glob that a PO did.
Then with a thin cutting disc "V" the cracks, either use a 41/2 " grinder as well as a dremel fitted with a disc.
Bumper gussets same.
use a flap wheel disc to clean it up afterwards
The frame can be straightened with the aid of a gass welding torch or cutting gun
The frame is mild steel not like chassis of today with carbon content
Where it`s twisted or bent heat it up red first,it will easily go back with a hammer and a steel backing block or a piece of heavy channel.
you can do the same with the bumper gussets.
Heat red then with a small hammer and dolly they will straighten out too.
Geoff Bull

[Wolfman]

One thing to watch when drilling a crack stop hole is be sure the hole is at the end of the crack. A hair line crack usually goes on past the "visible" crack. You drill the hole where you think the end is only to have the crack go on past the other side of the drilled hole.
Nice repair work DPCD. Instead of cutting the frame square, the "vee" cut spreads the stress out over a larger area. A square, perpendicular cut puts all the stress on a single line.
Grinding a "vee" in the weld joint gives the weld depth in the material instead of just sticking the weld on the surface.
On a channel, the load is carried by the top and bottom of the channel. The side add some strength but mainly keep the top and bottom stable. Lightening holes are cut in some frame sides to reduce weight and does not adversely affect the over all channel strength.
When welding a break across the top or bottom of a channel, a doubler welded across the weld will greatly increase the strength of the repair. An example of a doubler can be seen on the bottom of the frame in one of YGL80's pictures. A doubler can be placed on the inside as well as on the outside.