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Unread 06-30-2007, 02:59 PM   #1
justpicaname
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1994 YJ Wrangler 
 
Join Date: Feb 2006
Location: Ontario, Canada
Posts: 35
Frame repair

I have 2 bad spots on my 94 frame, front drivers side (at stearing box) and rear passanger side (at shackle). It's really bad (can post pics if needed) leafs might rip off frame soon.
I have to options to cut out the rotten metal and make a template cut a patch and weld it in, or I can just put more metal on top of the old stuff. I need to repair the face and bottom near the stearing box. And the rear has a divit in the frame where the shackle bolt goes though, that spot I will have to cut the old steel out for sure.
Now does anyone know the welding procedure for welding a frame? ie what rod what type of joint & gap. Also what grade steel do I use, and what thickness of steel?

I saw a frame reinforsment plate for gm trucks for there steering box but can't find one for a YJ, anyone ever see one? That might work for me.
Thanks

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Unread 06-30-2007, 03:28 PM   #2
leftlanetruckin
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cut out all the bad steel......
i used 1/8" flat stock on my old frame, worked fine.
2 1/2 flat will cover the top and bottom of the frame, and you can buy the frame repair section for the frame rail by the steering box, found mine on ebay a year or so ago, may wanna look there..
i just mig'd the sections on.....hell i'm a truck driver, if it isn't in the welder already, it dont get used....
regular .30 wire and shielding gas worked fine for me..

martin
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1998 XJ on 37's.JK Rubi axles with chromo shafts and ctm's, 4:1 transfer case, etc etc etc.The Cherylkee....
2003 Range Rover HSE, 4.4 Quad Cam.
1998 Range Rover 4.6 HSE
2000 4.7 4WD WJ with a rebuilt motor.
4.3/700r4/new frame buildup (YJ)....
http://www.jeepforum.com/forum/f12/swap-offically-underway-324622/

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Unread 06-30-2007, 04:37 PM   #3
noodle9
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1994 YJ Wrangler 
 
Join Date: Nov 2006
Location: michigan
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I have a 94 and I cut the bottom of the frame off and slid in some 2x2 with 1/8" wall and welded to the old metal after cutting out the bad parts. It is holding up great. Good luck.
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Unread 06-30-2007, 06:06 PM   #4
Joe Dillard
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1991 YJ Wrangler 
 
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Location: King George, VA
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If things look anything like this (this is not my YJ)....I'd cut the entire area out & replace it.



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Unread 06-30-2007, 07:20 PM   #5
justpicaname
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Ooch, mines not that bad yet. But wouldn't take long.

Thanks leftlanetruckin I'll check ebay. What did you do with the vert welds, fishplate them?
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Unread 07-01-2007, 02:39 PM   #6
leftlanetruckin
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Quote:
Originally Posted by justpicaname
Ooch, mines not that bad yet. But wouldn't take long.

Thanks leftlanetruckin I'll check ebay. What did you do with the vert welds, fishplate them?

yeppers!

martin
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1998 XJ on 37's.JK Rubi axles with chromo shafts and ctm's, 4:1 transfer case, etc etc etc.The Cherylkee....
2003 Range Rover HSE, 4.4 Quad Cam.
1998 Range Rover 4.6 HSE
2000 4.7 4WD WJ with a rebuilt motor.
4.3/700r4/new frame buildup (YJ)....
http://www.jeepforum.com/forum/showthread.php?t=324622

Years to gain the hands on experience, and offer it freely.
Minutes to gain the knowledge from the internet, and quote it just as freely.
Choose wisely!
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Unread 07-01-2007, 08:45 PM   #7
doug_1994
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Quote:
Originally Posted by justpicaname
Now does anyone know the welding procedure for welding a frame?

Here's a great write-up.

http://www.jeepforum.com/forum/showt...t=frame+repair


Doug
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Unread 07-04-2007, 10:04 AM   #8
justpicaname
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one more thing, on the back of the frame, where the rear shackle bolt goes through. Dose the steel need to have that indent, it's been done with some special countersink drillbit i guees. I think its there to add strenght to the area.
If this needs to be done what the easyest way to do it, or any alternatives.
Thanks again
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Unread 07-04-2007, 10:10 AM   #9
rustywrangler
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It doesn't need the indent. If you look at the write up posted above by doug, sentinal does not creat that indent. Just put a new piece of tubing in there and it will be plenty strong.
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Unread 07-04-2007, 10:18 AM   #10
justpicaname
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Quote:
Originally Posted by rustywrangler
It doesn't need the indent. If you look at the write up posted above by doug, sentinal does not creat that indent. Just put a new piece of tubing in there and it will be plenty strong.
ok, cool. But will this repair pass a safty inspection. Not sure who is more strickt U.S or Canada? I will be moving about a month after I do the repair, and will probbably have to change insurance, and get a safty check done. I hope I'll be able to pass.
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Unread 07-04-2007, 10:23 AM   #11
rustywrangler
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As long as you do it right and don't cut corners it should. Not shure what the canada regs are on it.
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Congenital Heart Disease is a reality for me, BOTH of my children have it. Please read up and become aware for future generations

Lydia Ann-Acquired 08/05/05 Open Heart surgery 08/10/05
Jacob Patrick-Acquired 01/17/08 Open Heart surgery 02/15/08
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Unread 07-04-2007, 11:35 AM   #12
leftlanetruckin
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done right, they wouldn't notice the repair for what it is!
at the most, it would look like some reinforcement for the rear of the frame...


martin
__________________
1998 XJ on 37's.JK Rubi axles with chromo shafts and ctm's, 4:1 transfer case, etc etc etc.The Cherylkee....
2003 Range Rover HSE, 4.4 Quad Cam.
1998 Range Rover 4.6 HSE
2000 4.7 4WD WJ with a rebuilt motor.
4.3/700r4/new frame buildup (YJ)....
http://www.jeepforum.com/forum/showthread.php?t=324622

Years to gain the hands on experience, and offer it freely.
Minutes to gain the knowledge from the internet, and quote it just as freely.
Choose wisely!
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Unread 07-04-2007, 02:47 PM   #13
ebproseller
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This is what you see !!!!!!!

I had the same thing as you, I've fix it and 1 year later I've found some other big holes, near the rear shock mount, beside the fuel filter ......

So i've baught another YJ with a good frame and swap it !
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Unread 05-19-2008, 10:34 AM   #14
justpicaname
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1994 YJ Wrangler 
 
Join Date: Feb 2006
Location: Ontario, Canada
Posts: 35
I got around to fixing my frame, I must say it wasn't as hard as I thought.
The jeep handles alot better now, dosn't feel like the wheels are going to jump off when I turn hard now!
Hear are some pics of the project

http://i78.photobucket.com/albums/j8...h2008006-1.jpg

after I cut out the bad stuff


http://i78.photobucket.com/albums/j8...rch2008008.jpg

even the inside was cracked bad



sorry guys can't post my pics anymore. (my post count got reset!)

http://i78.photobucket.com/albums/j8...rch2008016.jpg

starting the welding

http://i78.photobucket.com/albums/j8...rch2008017.jpg

adding the sleeves

http://i78.photobucket.com/albums/j8...rch2008027.jpg

welded in a new peace, then fishplated overtop.

http://i78.photobucket.com/albums/j8...rch2008031.jpg

all done!



I used 1/4" plate (alittle thick, but it was the thinest I could get from work)
First I removed the steering box,
then cut out the face of the frame, wow it was bad. I left the inside wall of the frame so it would stay strait.
the I made a template from cardboard, and fabed the peace. I put it inside the frame and welded(overhead & flat) to the old frame.
next I cut a strip of steel for the bottom (again I left the old metal there and weld to the new plate)
next I welded the sleaves for the bolts (steering box)
then I made another template to fill in where I cut the old steel (face of frame) I ground it down to fit exactly and gave it a slight bevel (for good weld penitration) Then welded it into place.
Then I fabed another plate to fishplate. this plate goes about 6-8 inches over good steel and back about 3-4 inches over my new plate.
I also welded up the crack across the top of the frame.
Then cleaned up with grinder and prime and paint.

It took me 2 full days, but I ran into MENY hard bolts....lol I couldn't even get the front wheel off, the lug nut was so stripped I tried everything, finally I used the welding machine to melt the lug nut off..lol amazing I didn't damage the aluminum rim.
Also I did all the brake , roters, and drums while I was at it.

It isn't a hard fix, I got all my supplys from work for free (steel, welding rod, grinding disks)
all it cost me was $60 for the welding machine for the weekend, and $15 for primer and paint.

Don't be affraid to do this repair, I put it off for a year, and I'm luckey the frame didn't snap, down the highway..

Last edited by justpicaname; 05-19-2008 at 10:50 AM..
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Unread 04-24-2010, 10:37 PM   #15
bismo183
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1992 YJ Wrangler 
 
Join Date: Apr 2010
Location: London ON
Posts: 1
Hello,
Just bought a 1992 Jeep, with a similar crack to what you had on the front end. Looks like you did a great job of fixing it! I noticed you're from Ontario too, have you had to get it safetied? Did they care that your frame was welded? I have a good friend who will weld it, and fabricate the part for me (also thought of buying a kit), but I am worried that if I do it, it still won't pass a safety.

I've only owned a jeep for a week, but I like this "brotherhood" already! Any advice would be greatly appreciated.
Thanks!

Bill
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