Frame Boxing/Reinforcing Without Kit, Pics?

[Adventure Teq]

Alright gang, after much deliberation I opted to repair this thing in the following fashion.

Perhaps it could have been done much better, but this is what I could manage with what I have.

 

[Adventure Teq]

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[Adventure Teq]

And there it is.

Perhaps I’ve got enough momentum after 3 years to go ahead and start my own FJ40 rebuild thread...

 

[middlecalf]

Awesome! I’m proceeding similarly, but was going to build the angle from flat stock. What gauge angle iron did you use? Can’t tell if your welder is 110 or 220, welds look great. And any info on the bead head bolts would be great.

 

[Martyt]

Wow, nice work. Nice beads on the welding and looks great overall!

 

[Adventure Teq]

Awesome! I’m proceeding similarly, but was going to build the angle from flat stock. What gauge angle iron did you use? Can’t tell if your welder is 110 or 220, welds look great. And any info on the bead head bolts would be great.

Thanks.

It was just basic 3/16” mild steel. I would have liked something higher carbon but this is what they had.

And they’re just standard 5/16” & 3/8” button heads from Fastenal. I used stainless split washers and locking nuts too. You can’t get torque on the Allen heads themselves so you gotta hold them with the Allen wrench then torque hard on the nuts. Hope they hold up til the Apocalypse at least.

My current welder is a 185 amp dual machine. Can use either 110 or 220. I’ve only ran this one on 110 with standard wire and argon. Could get more punch out of the 110 with Flux Cored wire in reverse polarity, but haven’t needed that or the 220 yet.

 

[sproggy]

Oh man, now I've seen everything! So cool. Amazing what can be done with the right know-how and determination. Simply amazing. Is that a TIG welder? I'm a complete novice to all this stuff but looking to learn. I wonder if not having perfectly round holes in the frame effects the flex ability? Based on your amazing work I was thinking you were going to re-shape those holes with a saw or torch. Does it matter? Certainly no better way to get inside that frame than cutting out the inner channel. Will be interesting also to see if everything bolts up alright with all you've done. Gonna subscribe! Keep on it!