Metal fatigue crack in right front wheel well

[fvunen]

Hi,
I noticed a fairly sizeable crack above the right front wheel well just ahead of the bulkhead. Upon closer inspection it shows all signs of metal fatigue. The car has done almost 300.000km , is accident free but has done a sizeable number of kms on (rough) tracks and sand dunes where a bump here or there is unavoidable. No signs of any detoriation on the left hand side. Has anybody seen or experienced something like this before?
Any suggestions for a fix? Simply welding it shut or rather welding a short strip of sheet metal over it?
Thanks!

 

[05ls430518]

Have you owned the vehicle since new? There are others more knowledgeable than me about offroading maybe they can chime in, but I think you would of had to duke's of hazzarded your truck to do something like that offroading.

 

[fvunen]

Have you owned the vehicle since new? There are others more knowledgeable than me about offroading maybe they can chime in, but I think you would of had to duke's of hazzarded your truck to do something like that offroading.

Yes, owned since new and as I said, an occasional bump is almost unavoidable when in the dunes. No "flights" however.

 

[RET2]

Yes, owned since new and as I said, an occasional bump is almost unavoidable when in the dunes. No "flights" however.

So no one held your beer ever?

 

[bloc]

Tbh I’d expect that type of crack from the body (not frame) over lots and lots of small vibration vs one big hit.

Do you know whether your body mounts are in good shape? Any way to compare them to those on a new 200? The bolt protruding through the frame mount more than a new rig would suggest sagging.

Also I’d try the Australian boards.. many more 200s there seeing long term off road duty.

As for a fix, I fear welding would just make it worse, as it would probably impact the crystalline structure of the metal where you do weld, and the metal is clearly already having issues with fatigue. Though the crack seems to head for the hole the harness is clipped into.. if so it may not spread anymore.

 

[nwfl4runner]

You need to pull that plastic trim up top to see where that crack terminates. I wouldn't want to just weld it back up, if you did anything I think you'd fishplate it on both sides, no need to 360 weld it either.

 

[turbo8]

I guess I should go check mine.. I'll report back soon.

 

[2021 LC200]

With the body on frame design (8 rubber blocks supporting the body) it is hard to believe this happened.

Did you perhaps loose one of these rubber supports putting high loads on that corner?

Or have oversized tires which hit the fender when fully depressed?

 

[turbo8]

No issues on mine. Any extra weight on your inner fender, like an extra battery, compressor, etc. ?

 

[Madtiger]

Reminds me of what happened to FJ Cruiser fender bulge issue.....

 

[TeCKis300]

This reminds me of a similar common crack/bulge issue with FJ cruisers. I didn't follow it close enough understand if it's only early model years or due to mods.

It seems like there's potentially several causal factors, including early versions that were too weak in this section. As I don't think this is common to the 200-series, perhaps consider some of the causal factors including modifications and can put load on the inner and outer fenders. Possibly things like batteries, armor that doesn't have enough clearance to the body skin, minor impacts, tire clearance and contact to the fenders. Looks like you have aftermarket outer fenders?

 

[doru]

We need to see the other end of the crack. Recommendations depend on that.
Welding, spot welding that is, can be a solution but requires adding a large plate over the area not just welding the crack. How big a plate and were to put the spots depends on what is there. Some disassembly will be required, including the removal of the fender.
You're basically looking at reinforcing the entire area using additional metal sheet.
The job is better left to a frame repair shop as they should have the proper steel, tools and skills to do a good job.
Just bolting a plate is not a good idea as it introduces additional (future) points of failure.

And as all people above alluded to, you do have to find the cause of it and fix it before trying to fix its effects.

 

[2021 LC200]

The job is better left to a frame repair shop as they should have the proper steel, tools and skills to do a good job.

And as all people above alluded to, you do have to find the cause of it and fix it before trying to fix its effects.

Exactly these, good luck and keep us posted!

 

[05ls430518]

Op do you live in a salt belt area by chance or drive the truck in or near an ocean?

 

[Boston Mangler]

Hard to tell in pic, Do you have a 2nd battery and tray installed?

I know A LOT of Tundra folks that had those issues when installing a second battery and the weight lead to crack due to how the bracket was designed.

There have since been new bracket designs to alleviate this.

 

[bjowett]

As mentioned, FJ Cruiser, also 2nd/3rd Gen Tacoma radiator supports, and 2nd Gen Tundra bed support channels…. anyone have any else to add?

It may have started at the hole and grown upwards.

 

[2021 LC200]

Tbh I’d expect that type of crack from the body (not frame) over lots and lots of small vibration vs one big hit.

Do you know whether your body mounts are in good shape? Any way to compare them to those on a new 200? The bolt protruding through the frame mount more than a new rig would suggest sagging.

This is the same aspect I would check. Some issue with the frame to body supports. Worn rubber, loose, damaged protrusions into the body etc.

 

[TimCFJ40]

I wouldn't sweat it too much honestly. The likelihood of that crack affecting performance or reliability is basically zero in a body on frame truck, and you'll make an unnecessary mess trying to weld/patch it up. My biggest concern with that crack would be the oxidation (rust) in the exposed metal portion, and welding it shut or welding a plate in would only open up an even bigger area to rust and corrosion. (burning through the paint on the back side, removing paint on the areas in and around the welds, etc).
Keep an eye on it and drive on.

 

[Boston Mangler]

I wouldn't sweat it too much honestly. The likelihood of that crack affecting performance or reliability is basically zero in a body on frame truck, and you'll make an unnecessary mess trying to weld/patch it up. My biggest concern with that crack would be the oxidation (rust) in the exposed metal portion, and welding it shut or welding a plate in would only open up an even bigger area to rust and corrosion. (burning through the paint on the back side, removing paint on the areas in and around the welds, etc).
Keep an eye on it and drive on.

STRONGLY disgreee here!!!

If you have a large crack in your body, I’d strongly advise finding/fixing the cause.

 

[gluaisrothai]

Aircraft owner here. Before you do anything else, stop drill the crack. That should buy you a few years.