Frame rail repair

[mbalbritton]

So the 50 year old frame is in need of some attention. Sure would be nice to build a new frame, but that’s not in the cards unless Dogecoin hits about $5.

anywhooo, What I’m looking at is 2’ section of driver side frame rail where the OE muffler would have hung is rusted out. This frame is boxed from 2 C channels and the bottom face inboard side and lower half of the inboard rail is rotted away. Top and outside is in decent condition, just need to clean off old coating.

So I’ve been putting myself through a YouTube degree in frame repair. I’ve found different theories from scabbing on plate to cutting away and butt welding replacement.

I don’t like the idea of scabbing, so I’m more inclined to butt weld. Here’s some Picts for what it’s worth of the location and a piece of 2x4 tube with 3/16 wall that I cut to make 2 L brackets to start from.

any input or experience is appreciated.

 

[rodney eppes]

Fabricators?

 

[paradisePWoffrd]

I would figure out where the frame is good again, first. The find a piece of box tube that fits inside or outside of it, and weld that in place. Then fish plate over the seams.

 

[Jeffncs]

You definitely need to get back to solid metal. I always use an internal sleeve to increase the repair piece length.

I use that internal piece for plug welding to the frame and repair piece. The actual replacement piece also gets plug welded to that interior flat bar and solid welded at the seam.

While it’s open, hit is all with a rust converter or other weld-through rust treatment/preventer.

 

[rodney eppes]

I'm thinking some company makes replacement sections. Maybe I can go back to a couple frame repair write-ups, & find that.

 

[Caver Dave]

Definitely a weird spot... given most break behind the front (fixed) hangers. Appears someone cut "access holes" on the inside to get to the rivets holding rear outboarded hanger?

How's the other side/rest of the frame?

 

[Caver Dave]

I'm thinking some company makes replacement sections. Maybe I can go back to a couple frame repair write-ups, & find that.

For every other Jeep on the planet, but not a Jeepster/Commando.
With a little over 65k made (1/2 of the lowest single CJ5 production year), simply no market...

Not saying a donor YJ/TJ/etc. frame or patch section isn't doable...