Frame Repair and Reinforcement
Frame Repair and Reinforcement
General Equipment
3 Phase Inverter Spot Welder 254-00002
Compuspot 700F Welder 190-50080
I4 Inverter Spot Welder 254-00014
Inverter Welder with MIG Welder 254-00015
Material:
Welding Precautions
WARNING:
- Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.
- Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.
NOTE: Whenever factory E-coat has been removed by sanding, grinding or weld burn-off, corrosion protection must be restored. For additional information, refer to Restoring Corrosion Protection Following Repair.
1. If welding must be done on a frame, make sure the following requirements are met:
- If the frame is attached to the vehicle, the battery ground cable must be disconnected before using any electrical welding equipment.
- Do not use gas welding equipment.
- Use a temperature-indicating crayon to make sure that the temperature does not exceed 750 °C (1,400 °F).
- Install new spot-welded components by spot welding where possible. If spot welding is not possible, use plug welding.
Frame Straightening
WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if damaged. Straighten damaged frame rails to correct frame dimensions prior to frame member sectioning. Failure to follow these instructions may adversely affect frame rail performance and may result in serious personal injury to vehicle occupant(s).
NOTE: Whenever factory E-coat has been removed by sanding, grinding or weld burn-off, corrosion protection must be restored.
1. If heat is needed to straighten a frame member, keep the temperature below 650 °C (1,200 °F) (a dull red glow). A temperature-sensitive thermal melt crayon should be used to monitor heat buildup.
- Heat should be kept to a minimum area so that the hardness of the metal will not be affected.
- Straightening should only be attempted on frames that fail to meet specifications or where damage is apparent. For additional information, refer to Specifications / Dimensions.
- Straightening should be limited to parts which are not severely bent.
- Reposition or shield any fuel lines, brake lines or wiring harnesses or components in heated area.
Underbody Misalignment Check
NOTE:
- Underbody misalignment can be the result of damage or loose frame components. It can affect front and rear wheel alignment and cause incorrect operation and abnormal wear of tires and chassis parts.
- For additional information, refer to Specifications / Dimensions. , for dimensional data when carrying out repairs on the frame.
1. Inspect the frame for damage and loose parts before checking the frame alignment.
- Inspect all cross members for cracks, twists or bends.
- Inspect all of the welded connections for cracks.
- Check all of the support brackets for looseness.
Frame Reinforcement
1. After a bent frame member has been straightened, inspect the frame member closely for cracks. If any cracks are located, the damage must be welded and, if necessary, reinforced.
2. The following steps detail the recommended frame crack repair procedure:
- Stop drill the crack(s) at the end.
- V-grind the crack(s) in preparation for welding.
- Weld the crack(s).
- Grind off the weld excess.
- Add a reinforcing plate if necessary. The reinforcing plate must be made from flat or angle stock of the same material and thickness as the frame member being reinforced, and must extend to either side of the crack. Ideally, the reinforcement will be cut from the corresponding area of a similar frame.
- Weld the reinforcing plate entirely, using the skip weld method to reduce potential heat buildup from concentrating in any one particular area during repair.