Frame Repair: suggestions

[4WDTraveller]

Just wondering what is the best metal to use to weld in a frame rust repair? I have about a 5-inch ugly rust hole behind the muffler I need to cut out, weld up, and seal with POR or something.

Any specific metal size/source someone can recommend for TLC 60-series frame repairs?

Thx...

[RogerM]

Only one hole?? Get the pointy hammer out and give the whole chassis a good whacking. The sound of good steel versus paint and rust is distinctive.

The sections behind the front spring hangers and above the axles went on mine and was pointless trying to repair, coal dust and salt water did the damage.

If there is a wrecker nearby, get some steel from another chassis and use that. Failing that, use some mild steel plate, drill a hole near the welds and give the steel a damn good coat of rust proofing.

[4WDTraveller]

I've hammered most of the frame, and the rest isn't too bad for rust. The one hole is directly next to the muffler...who says heat is good?

I'll probably weld in some patches, but what is the point of drilling holes near the welds? Water/air flow I'm guessing...

[diesel jim]

Cut out the old rusty stuff, try and makes "straight" edges, then get some plate the same thickness as the orgiginal chassis... little point in using thicker stuff as the rest of the chassis will be weaker.


try and overlap the edge of the "hole" by 1/2~1" or so. continous welding too.

[RogerM]

Originally Posted by 4WDTraveller

I'll probably weld in some patches, but what is the point of drilling holes near the welds? Water/air flow I'm guessing...

You need to get the rust proofing onto the bare metal inside the chassis rails, or face the same rusted out chassis in a few months.