Big day today! Well, didn't get as far as I needed to, but I'll get the rest done in the AM in time to get it back to the power coaters.
First, don't the motor mounts look good with a new coat of black paint?
The freshly blasted raw frame came home today -- and there are a few problems we'll need to address...
The inside of the middle cross member was, well, perforated. Dang! Not just the bottom. The sides will need some attention too (although they are nowhere as bad!).
The front, driver side spring mount weld split in the crash -- will need to weld that!
End view of the same frame rail about half way fixed. The other side is also bent - although not as much and without any twist like this one.
Step 1 -- Double up the bottom inside of the cross member
With the inner reinforcement in place
Next -- FLIP! The bottom of the cross member -- I had trouble laying a bead where the metal was super thin.
Working the 1/8" plate across the underside of the cross member -- essentially doubling up the double up.
Formed up and heavily tacked into place
Next, I welded the entire seam and then ground the sides flat
I also made 10 new frame straps that I'll be able to add where I think they will help -- there are two on the cross member cover I will be putting back on, but I'll take a quick look and add more if I think they'll help! They're just strips of 16 gauge with a hole that I'll use for a plug-weld.
Projects for the morning --- Put reinforcing sides on the cross member -- I have them plasma cut to shape (boy I must have been drunk when plasma cutting! It's hard to trace a line with all the sparks!). Then the edges will be rounded over to make the repair less obvious as it will look like the original. Although I'm going to put in two or three somewhat larger holes for drainage in hopes it will not get compacted. Plus, I'll be running a weld bead around the inside of the hole to stick the layers together so water can't get between them easily.
- Grind back the weld crack on the spring mount (I'll closely inspect and fix the other front spring mount if needed).
- FLIP! then the inside of the cross member will be coated with galvanizing spray to resist a future re-rust out! I'll put the cover back on the cross member.
- Then it's back for some powder love!
Happy Tuesday!
John