Welding on factory frames Tua’h (1 Viewer)

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Welding on factory frames,



I think we need a light-hearted approach to discussing topics on a discussion board so I’ll start.

Hey @gonzopancho I apologize if I hurt your feelers asking questions about welding on factory frames, your frame looks pretty with all those new welds! If you want to un-lock your thread I’ll go remove all my questions there.

So my question still remains for anyone that has real knowledge, took a class 35 years ago in college or can point to any real facts on the internet that debunk the broadly accepted practices about welding on factory frames.

@Cruisers and Co started to have a discussion when he said “The crystalline structure does change when you weld something but wrapping helps prevent a point of stress concentrations by dispersing the load around a bend rather than stoping at a point.” And I found that interesting and never thought about it but it makes sense to me, I will use that strategy next time I have a vertical weld thank you!

I had asked your opinion about four top to bottom vertical welds within 6” on a frame and I’m genuinely interested in your thoughts. I understand if you don’t want to answer and I won’t put you on the spot and ask again.

That frame appeared to be suspended on a rotisserie only on the ends of the frame and welded along its length in various spots in various directions, as was said I don’t believe it will ever be a problem on that vehicle but it brings up the question what is necessary, what is old timer rule of thumb verses what is based in science and engineering.

My “opinion” is that goes against everything I’ve been told or read personally and goes against any advice I’ve seen anyone ever give a new person in our hobby looking to weld on their frame. I was given my fabrication foundation 43 year ago by an old-timer then so my base information is probably 80 years old and I’ve never questioned it but I’m always open to hearing about new ideas and sharing what I believe with others.

So let’s question what we believe together and try to match some facts with some old-timer rule of thumb..
 
^^ this is exactly why this forum is so good, everyone learns from the contributions.
 
^^ this is exactly why this forum is so good, everyone learns from the contributions.
Lot's of good info on the internet but this has some good conversation with some of our local Mudd guys. I know @SNLC @cruisermatt @NCFJ come down to the STY occasionally and maybe one of them would be willing to share with us if their opinion has changed in the last four years from what they talk about in this thread.

I don't want to speak for anyone but the question was asked in that thread and got me thinking.
"Have you ever seen a broken frame from what you believe to be improper technique?"

I know apples and oranges but the answer for me is yes, it was vertical weld repair on equipment trailers or implements that seen heavy use and we would repair this kind of stuff fairly frequently. Although I believe the process should be the same to avoid potential issues I do not have first hand knowledge of a Toyota frame failure that was welded in a way contrary to what I believe to be correct.
 
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I am a Mechanical Engineer, but this Topic I have not Studied.

Frames on Cruisers are Full Tube.
The Tubes are Multiple Layers.
They definitely Over Built.

Tundras & Tacomas have "C" Shape Frames and are open which makes them much easier to Clean & Coat (Fluid Film)

I'd post pictures of Any Repairs both before and after so we can all Learn.

I'm having Body Repair Done on my 05 GX470 Next Month, but the Hanger and Body is Getting Replaced - Indirectly the Frame.
Toyota Sells New Body Mounts ($75). Will Cut Off Mount, Clean out Tube, then Plate Frame and Weld Mount.

**My Neighbor said that Vertical welds on Commercial Frames Dangerous - I made a Mental Note, but never Verified. I trust him.

Hole in Frame.webp
 
I'd post pictures of Any Repairs both before and after so we can all Learn.
For context these photos show some vertical welds that were posted on another thread. They are part of a beautification project and those welds are on top of existing factory welds.
IMG_1395.webp


IMG_1396 (1).webp

The frame appears to be on a rotisserie and not on a frame table when this work was done. The question is "even through this goes against everything some of us think we know does any of it really matter"
 
@Hornd your neighbors right. @J Mack welding a frome on a rotissire instead of a platen or frame table is like welding in floor pans without cross bracing the pillars🤔🧐 You are asking for trouble. And if the heat is focused all in that 1 spot at the same time you are gonna cause more than distortion, it will jeapordize structual integrity. I've been doing this for a lot of years with all types of materials in precision, military, structural, and pipefitting. I've seen all types of welds on all types of materials, and would not weld over anyone elses weld without total removal 1st🤔🧐 no matter how pretty.
 
I am a Mechanical Engineer, but this Topic I have not Studied.
You need to spend some time looking at Mr @RUSH55 Fly-By-Night frame mods, hopefully he'll post more pictures of his work and talk about it here, but the guy crossed every T and dotted every I when it comes to the "rule of thumb" this is what's acceptable thing and clearly went out of his way to do it with style. He works out of a small garage and his driveway and builds some really cool stuff with basic hand tools..



I'm having Body Repair Done on my 05 GX470 Next Month, but the Hanger and Body is Getting Replaced - Indirectly the Frame.
Some interesting information here..

 
@J Mack You don’t remember I thought those were to ur welds on that front cross member ?


No I bought off bat. Had it shipped out to Oregon to my folks to do some work on before shipping it to Hawaii. Rebuilt front axle, bearings hubs seals all the typical front end stuff, drivelines, brakes all the way thru. Plumbed in a heater and defrost tubes, swapped out front grille and aprons for 40s stuff, welded up the frame in acouple spots from a lifetime of abuse. Then had it shipped to Hawaii. This was the day after they picked it up in southern Oregon and it fell off the transport truck on the grapevine. Then got smacked by a semi as it rolled down I-5. Was an insurance nightmare all the way around.
 
@J Mack You don’t remember I thought those were to ur welds on that front cross member ?
I literally just bought my first Chinese welder and I’m still watching YouTube videos trying to figure out what the buttons do, I would be proud to call that one of my welds!!
 
I stick to what I originally said in my linked thread above.

I do think things like body mounts are not as crucial as cutting a frame in half and splicing it back together. We use a variety of tools when we do this kind of work.

If you are worried, get it on a frame machine after mods and see how true it is. I have done that and was at least a little surprised how true it actually was.

The arguments on welds get pretty endless. We like to stick to pretty general, tried and true techniques. As mentioned in my linked thread, go read and or watch videos about hot rod and rat rod chassis building.

Cheers
 
I stick to what I originally said in my linked thread above.
Thank you Sir...
I appreciate your response, we live in the same town and I feel like we should get together some time...
Do you have any advice for a new guy wanting to work on his own stuff??
 
Well, manure. I sure hope my frame doesn’t slip on a banana peel! Not counting what I’ve already done to it, I’ve still got to weld on shock towers, and there’s a fair amount of vert on them!

I guess it makes sense. Hopefully the box tube frame counteracts my previous ignorance induced confidence…
 
Hopefully the box tube frame counteracts my previous ignorance induced confidence…
We have some really smart guys here on Mudd, I'm hoping we can get a few to actually engage us in conversation then we can ask questions about what we believe verses what we read on the internet or was thought years ago by a guy that did the job...
Times have changed and so has processes and we all need to be willing to learn!
 
10/4. Class in sesh.
 

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