Need advice on pontoon trailer repair.

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Hello, Ive been a lurker for a while and finally run across something I need some pro advice on. I have an old pontoon boat and trailer my father picked up on the cheap.....really cheap; because of the work it needs. The trailer has seen better days and was exposed to salt water for some period of time according to the original owner. Long story short I need some advice on whether to go ahead and repair the trailer or sell/scrap it and start over with a new one. I have attached several pics. below of the rust damage, its pretty severe. My plan was to find some "C" channel the exact same size as the rusted out sections which is 8 x 1 1/2 x .25, cut out all of the rusted sections, weld in the new channel and fish plate both sides of the newly welded channel. Is that a good plan or not? I've been welding for approx. 5yrs. now with 6011 / 7018 and have become quite good at it. I'm just not sure how to do this repair and make it structurally sound, so I'm coming to you guys for advice. I'm looking to do it right, so if you any concerns or advice let me hear it. Attached ImagesLast edited by Miller3m; 01-04-2015 at 05:41 PM.Reason: spelled title wrong
Reply:Rust looks bad enough I'd probably just scrap everything I see in those picts. I wouldn't bother with the hassle of chopping it all up into little pieces and trying to splice it all back together. It would be faster/simpler to simply start from scratch..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Hey Miller3m. Welcome to weldingweb!  I deal with this type of stuff everyday.1st word of advice.  Before you do anything take measurements and make a drawing.  You'll save a ton of headache if you have everything laid out before you begin.Your starbord side rail is wasted.  More than 50% of the material is wasted away.  I would make a new frame.  Then weld or bold the guide rails to the new frame.The guide rails brackets dont look to bad. But if u need to build new ones.The other concern is thats all galvinized steel.    Welding, cutting, or grinding galvi you will need a respirator for sure.   Welding on galvanized use 6010 or 6011.   It will burn thru that galvi coating.  Post pics of your progress. We all love to help.  Ask us anything Last edited by galencwi; 01-04-2015 at 06:17 PM.“I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair
Reply:One more thing use a little anti sieze on the stainless bolts.  Try getting them off if they have been torqued down!  Lol. “I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair
Reply:I don't know enough about that sort of repair to help.  But, if you decide to build from new, I'd make measurements of that trailer and the material used...then just duplicate the design.Maybe if you wrap more electrical tape around that rust, it will be OK.  ;-)KevKevin / Machine_Punk from The Aerodrome Studio - Lincoln PowerMIG 210 MP - Meco N Midget w/custom welding station - Vintage Victor 100Current Projects: The Aerodrome Studio
Reply:Start over or find another trailer.   Price the C8 and see but you'll probably be just as well off keeping an eye out for another trailer.  Either way, that trailer would be simple enough to build that for the time it would take to patch you would have quite a bit done on a new one.
Reply:At least you have the most expensive and hard to find parts.   The axles“I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair
Reply:I would agree with the majority here and say that if you put any value on your time you will be better off starting over. And that galvanized stuff is dangerous as well. Before you go too far you should check that front axle out close, it looks bent in the last pic. If that axle is bent there is little value in saving this trailer. If you really want to salvage some I would cut the rails behind the radius and replace the whole side rails, keeping just the tongue and saddles.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:I agree - use it for a pattern and weld up a new frame.It's faster than fixing and is an easy structure to make.Good luck and post pics Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Thanks for all of the quick responses; I think were just going to start over or pick one up off of c-list. The rust is just really bad, I didn't really get any pics of the cross members, but they are all rusted out at the joints. I think the axles are still good, they aren't bent. I haven't pulled the wheels off and inspected the spindles yet.... I'm not expecting much just based on the rest of the trailer. Im down here in Fl so im not use to seeing and dealing with rust this bad. I was surprised how the galvanized coating didn't really protect the welds; every welded spot it is pretty much eaten up and rusted through. The guy told me he built the trailer himself and had it dipped, I would have thought the galvanized coating would have protected the welds as well as it did the base metal?
Reply:Are you going to use it on the road a lot or do you just pull the boat out close to home and store it at the end of the season? Are the axles an springs ok?
Reply:Originally Posted by blackbartAre you going to use it on the road a lot or do you just pull the boat out close to home and store it at the end of the season? Are the axles an springs ok?
Reply:With all the corrosion showing, I'd be suspect on the condition of the axles despite what they may look like. I've seen too many where the tubes rotted from the inside out, but looked fine on the outside.Enclosed tubes almost always want to hold moisture. Submerging one underwater, is just asking for water pressure to find any pinholes or missed sections to push water inside where it will stay..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:goto tractor supply and grab some new axles and hardware, that boat doest weigh that much , just check the reg for weight and get proper sized axles.....it will be much cheaper and safer in the long run, just copy that trailer piece by piece...you can make a small utility trailer for off road ONLY with the old trailer...Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:best case scenario wait till scrap steel gets over $200+ a ton usually in the summer time.   Drop the boat in the water scrap the trailer and load up ur boat on the new trailer you built.  lol“I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair