Crack in my frame

[Toms01PSD]

I wans't sure where to stick this so mods please move it where you see fit.

While installing my new Bilsteins I found a hairline crack by the drivers side upper shock mount. It's been about a week and half since i've discovered it and it appears to me that it has gotten worse. Before I throw more money into this thing i'd like some professional opinions as to what I should do. I hate to be out on the road and put others in danger or be on a trail and my frame just snaps in half. It hasn't cracked all the way up the side of the frame but it starts at the bottom and is getting progessively worse going up. How could I repair this, if at all? Here's two pictures. When I get it on a lift I will take some better pictures but that may be awhile. It only goes up the "O" in the frame you can see in the second picture and it's not visible when looking on the other side of the frame. The only thing you can see from the other side is the crack where the frame has actually split at.

The truck is only a 99 but I have replaced a section of the rear frame before and some chunks of the crossmembers have rusted out. The cross member across the gas tank is also rusted through pretty good on the passenger side where it's attached to the frame.

 

[177CIOfPureLove]

Well, what I would do is drill a 1/8 or 1/16 hole where the crack stops, to further prevent it from cracking. Vee out the crack clean it up good and have it welded, that is unless of course you can weld at the level needed to perform this repair, which respectively, most likely is not the case. Doubt it would ever return. And if it did, well, I would cut pieces of 1/8th and fishplate the frame front and back.

 

[Toms01PSD]

Thanks for mentioning that. I have never welded. I will be learning how to at my local community college this upcoming semester. There are quite a few people around me that know how to weld but would it even be worth it with the rotted out cross members? When I replaced my brake lines I was literally pulling chunks of rust off the inside of the frame rails and pieces of the cross members are literally missing.

 

[177CIOfPureLove]

Taking the class will be a good experience for you! The very best thing to do would to try and make it an example for the class, even fab new x- members as well as learning to vee and drill cracks, and even fishplating! Although I guess you need it fixed soon. I would prob vote to rebuild all that is rotted, take your bed off and wire wheel your frame down and paint it to prevent anymore!

 

[Will]

It looks like the crack goes through the flange and is already as far as it can go--it's too late to contain with drill holes. That thing is in big trouble. It will come apart quickly now.

You need to weld in a reinforcement. A piece of 3/16"T angle, as long as can fit in there to reinforce the bottom flange and go maybe 2/3 of the way up the side. I'll see if I can find a picture.

Edit: These are instructions for lengthening a frame. It's the same basic procedure. I would follow this. Just welding it straight up will cause it to fail again. I've had 2 former plow trucks with broken frames ('68 International Harvester and an '87 K30) and both were just welded and then broke again in the same spot and then retired.

 

[Toms01PSD]

The thing that gets me is it's only a 99. I wouldn't expect this kind of rust or problems for such a "newer" vehicle. Would it be a good idea to wire wheel down the frame and paint it with something to refinish the frame until I go back for the next semester and then have it repaired? Should I quit driving it in the meantime until I have to go back?

 

[baxtej44]

maybe?

 

[Toms01PSD]

maybe?

If only it were that easy.

Is the kind of wire wheel you guys had in mind?http://www.lowes.com/lowes/lkn?action=productDetail&productId=77594-70-DW4930

Or something smaller? I have one in the garage but i've never used it on metal. I mainly used it to clean off brick after doing brick work in the yard.

EDIT: I'm running to good ol AZ now to pick up some stuff. I'm going to pull the bed when I get back and start wire-wheeling it. Should I lay down some primer on the bare frame and then POR-15 it or what? I don't know jack about frame prep so i'm looking for some good info. Be back in a bit!

 

[warrior24]

enjoy our heat!

 

[Sasquatch_Ryda]

I usually use a knotted wire brush cup on my angle grinder. Makes quick work of surface rust. POR15 actually doesn't like to stick to bare metal, all you have to do for it to work best is to remove the loose rust scale and paint it on.

 

[Toms01PSD]

I usually use a knotted wire brush cup on my angle grinder. Makes quick work of surface rust. POR15 actually doesn't like to stick to bare metal, all you have to do for it to work best is to remove the loose rust scale and paint it on.

I'd rather take it down to bare metal and go from there. I bought some clean metal primer so i'm going to spray that on once I get it all done. Would POR-15 go on over the primer and hold?

EDIT: Thanks for the help so far guys. I'll be back after I yank the bed. I'll take lots of pictures of the frame and whatnot. See if it's worth salvaging.

 

[Mark_88]

I had an opportunity to buy a 93 Ranger where the shock mount was actually torn away from the frame...but the guy said they were easy enough to fix...just cut it off and weld on a good one...but if you can fix it with a brace then it may be good enough...

I wouldn't trust that myself because the metal might just crack some where else...looks like they may have used an inferior part to begin with...

Edit...never mind the above...it's the rear end of the frame and that can be fixed with a good sized brace...but I would clean up the rest of the frame and have a good look at it for other possible areas that may need attention...

 

[Toms01PSD]

I just got all the bolts off and i'm about to pull the bed in a minute. This weather is killing me.

The shock mounts are not the issue, the issue is a crack in the frame. I don't see what you mean by inferior part? It's the frame from 99?

 

[Mark_88]

I just got all the bolts off and i'm about to pull the bed in a minute. This weather is killing me.

The shock mounts are not the issue, the issue is a crack in the frame. I don't see what you mean by inferior part? It's the frame from 99?

Yeah, I know...that's why I took another look at the pic and then edited my post...for some reason it looked like a shock/spring tower...

 

[Roadkill]

If you could afford a new car you could get $4500 for it.