Frame Replacement..

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I have pics but no computer to upload them with.....yet.2002 Chebby Avalanche..Marc's truck..just turned 100K..The frame from 10" behind the front wheels to 12" before the rear wheels is GONE!Talk about rust!!!!!!!Torsion bar crossmember..Tranny and transfer case crossmember ready to fallout!!!Took the body mounts out by hand!!!Got it up in the air and started chopping...We went and found a 2005 Suburban in the scrapyard and they flipped it over and cut the complete frame out for us for 500$This frame is in GREAT shape...The Suburban was burned and only had 65K on the ticker..Got it to Marcs house and had at it.Drivers side is done and tomorrow we tackle the pass side.New body mounts and everything..It's amazing what a sawzall and good blades will do..Fired up the "Dip Stick" Airco mig and it welded like a champ!Had to remove the gas tank and exhaust to open up things but so far so good..Next week when I get my new computer I'll post up the pics..Just wait until you see this!  Don't ever say "It can't be done" because yes it can if ya know what you are doing and I must admit me and Marc make a GREAT team!If Tozzi was there with us it would be done in a matter of hours but it's just the 2 of us so far..Well I am covered in grinding dust and RUST so it's off to the shower and then it's  time!!Believe me when I type this now..We get all the FUN jobs......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Looking forward to the pics. My bud has a avalanche, sounds like I hope we never have to do his. If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:Thats a lot of work you have there I can't wait for the photos. I was replacing frames on 2000-2003 Toyota Tundras and 2001 - 2004 Tacomas, however I at least got a new frame and some other related parts but most of the old rusty crap had to be reused. At first Toyota was buying back some of the Tacomas until they got replacement frames, then they began giving away the frames under warranty. I didn't see any as bad as what your describing. That started somewhere around 4 or 5 years ago or so if I remember correctly. I'm pretty sure Chevy would probably tell you sorry about your luck, but is there any chance you checked into any manufacturer assistance with that?Millermatic 135Craftsman 7 Hp 80 Gallon           2 stage compressor
Reply:Originally Posted by 70Challenger but is there any chance you checked into any manufacturer assistance with that?
Reply:You got me beat!!! I use two lifts and borrow a couple guys in the shop when necessary.Millermatic 135Craftsman 7 Hp 80 Gallon           2 stage compressor
Reply:Very nice project, but is a 11 year old Avalanche really worth all that work and money? Don't have any idea about what it's worth, especially since I'm in another part of the world, but around here cars that age usually get scrapped instead of repaired when there is such a major problem. No point in spending more than it's worth on fixing it.Anyway. Make sure you give the new frame and everything else you get access to a good rust protection, so it survives as long as possible.
Reply:Seems pretty young to me . . . the last vehicle I retired was 23 (sold, not scrapped - it just plain wasn't enough to towmy new trailer) and the next oldest is 16 . . . and both still look good, and everything works. I don't, however, live in the rust belt, and that helps a lot . . . I also don't buy into the "don't put in more than it's worth" argument - I think that comes from folks who sell cars.  I look at two things: Will it still meet my needs?Is it cheaper than replacement?IE $5000 to repair a $3000 truck vs replacement at $50,000 . . . to me, the choice is obvious.- TimLast edited by tadawson; 07-14-2013 at 12:53 PM.
Reply:Originally Posted by 70Challenger At first Toyota was buying back some of the Tacomas until they got replacement frames, then they began giving away the frames under warranty.
Reply:Well... I think you compare apples and oranges. The replacement for a broken down $3000 truck is another $3000 truck, or something in that range. Spending 15 times that isn't a replacement, it's a pretty serious upgrade.A $5000 repair on that same truck may be a great idea if it fixes all potentially expensive problems, but if you have another expensive breakdown next week that truck has turned into a very deep money pit. If you had bought another $3-4-5000 truck of the same model and saved the old one for parts you would have been way better of.But it's all theoretical. You never know until it's all done, and at that point hindsight isn't going to help anyone.
Reply:I have read all the posts so far and here is the bottom line..There is not one spot of rust anywhere on the body..I took a real good look around under it everywhere this AM and it's absolutely PERFECT!Except for the frame where we replaced it.Still blows my mind how bad the frame was and only in the middle.The interior is mint..No dings/dents.on the body...Nothing!Passenger side was completed this AM and it was a piece of cake compared to the other side..New body mounts...Everything lined up perfect and after dressing the frame cuts it could not have gone any better.He is going to put it all back together this week and next Saturday it's going for a full sandblast underneeth and chassis paint.Then we will install the gas tank and inner fenderwells etc. after it's done.I have driven this thing MANY times coming home from sleddin and just....WOW...What I like about this whole project is the fact that we can still do this sort of stuff on your back and in the grass/dirt heat humidity and yuck all around and still pull it off..Not too many people would not even attempt this even with a lift and all the fancy this and that..I can not remember when the last time was that I got up and went back under and got up and want back under in 2 days...My back..Neck..Left shoulder..Hips..Knees..Arms..Are not very happy with me right about now but too bad..It's done.I got pics of it all so hopefully I get my new computer soon...Ahhhhhhhhhhhhhhhhhhhhhh time for moreTotal cost after finishing around 2500$Not bad compared to getting something else......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:good on ya. i'm sure its a proper job. makes the day job look like heaven right.
Reply:I would have done it and have done it. I went a bit more custom but same idea really. I started with a 79 Bronco and ended up with a really short 96 F150. It's not done yet, I only work on it when i have the time and that's not much. She still needs wired and painted but I'm getting there. (Home)Miller Maxstar 152 (sold)MM211/spool gunLincoln AC 225C(Work)Dynasty 350Powcon 300STLincoln SP-175TWeldlodgic AWS150sWeldlodgic AWS300Custom Resistance seam weldersCambridge Vacuum EB weldersI smell something burning.
Reply:Originally Posted by dbl612good on ya. i'm sure its a proper job. makes the day job look like heaven right.
Reply:Originally Posted by atariI would have done it and have done it. I went a bit more custom but same idea really. I started with a 79 Bronco and ended up with a really short 96 F150. It's not done yet, I only work on it when i have the time and that's not much. She still needs wired and painted but I'm getting there.
Reply:Originally Posted by OxfordAssuming your flat rate, what kind of times do give you for warranty work?  Can you make out on it?  I remember some warranty jobs you could make out well on, others not so much.
Reply:Originally Posted by zapsterNice truck!Post pics when done!!Yep!Nothing like crawling around on the ground......zap!
Reply:The only time I have seen the middle rotted out of a frame like you have described it is whan a custom exhaust pipe discharge is aimed right at the rotted area and I live in salt countryGordie -- "I believe you understand what you think I said, but I'm not sure you realize that what you heard is not what I meant."
Reply:PICS OR BAN!  ~heads to penalty box with a six pack~-AaronJet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:waiting with baited breath for the welding porn. should have gotten the next day delivery on the new computer Zap, you're killing us.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:Throw them on a thumb drive and use the library computer!!! MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:My 98 Chevy has 272.7k on it.My neighbor says that Brake lines are rotted out along with the Gas line.He/We never checked the frame that close....
Reply:Funny how nobody is questioning this repair considering it is going on the road, but God forbid someone wants to build a small trailer.............I am not questioning zaps ability and that is probably why nothing negative has been posted, including this one.Tim Beeker.
Reply:Perceptive comment there tnjind!Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Originally Posted by tnjindFunny how nobody is questioning this repair considering it is going on the road, but God forbid someone wants to build a small trailer.............I am not questioning zaps ability and that is probably why nothing negative has been posted, including this one.
Reply:I want to see them up so we can hear all those that say it shouldn't have been done.Sure glad I wasn't a member posting photos when I used to stretch all those truck frames for wrecker and rollback bodies.   I can imagine the comments regarding the 80,000# hydraulic under-reaches and hydraulic stifflegs too. MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!you will note that the people doing the work are well known members, who have shown that their abilities and equipement are more than up for the task of performing such a repair.  You will also note that on many of the trailer builds that come up, they are 1) first time project or novice at best weldors. 2) the equipment that is being used is subpar or simply not up to the task at hand. 3) forrum members who have little to no posting history. where as this doesn't mean anything for actual ability, it does give people an idea of whether or not the person is up to the task at hand. That is not to say that all trailer threads are thought of negatively. Take my trailer build for example. there was no popcorn pass around and very few negative comments. If the poster gives the right information, and asked the right questions a trailer build thread can be quite pleasant.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:duane, most of the overreacting posters screaming bloody murder about trailer repairs and mods couldn't carry your lunch box. probably don't even know how an under reach attaches to a frame, but i'm sure they could critique your work. keep it up we need your insight on this site.
Reply:Originally Posted by duaneb55I want to see them up so we can hear all those that say it shouldn't have been done.Sure glad I wasn't a member posting photos when I used to stretch all those truck frames for wrecker and rollback bodies.   I can imagine the comments regarding the 80,000# hydraulic under-reaches and hydraulic stifflegs too.
Reply:This has all been very interesting..I just got on here with my NEW confuser...EVERYTHING is so different now..Must upload printer again and figure out what the hell is going on..Just to clarify things we cut out the bad stuff and grafted in the new stuff...All the crossmembers fit like a glove...Body mounts perfect..All the doors still open and shut like they should..Here are a few pics to get started with..No particular order but you'll get the picture soon enough...Now let me see about the rest of this......zap!Last edited by zapster; 07-15-2013 at 09:16 PM.I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Looks like a Lot of, uh fun.Tim Beeker.
Reply:Did you stub inside or fishplate?Tim Beeker.
Reply:Couple more..These frame grafts came out just fine!New body mounts in place...He will put fishmouth plates over the graft welds..We took out the Y pipe so we could get to the inside with nothing in the way..Lots-o-work but........Trust me guys..What we did is 1000 times better that what "was" there...I will get more pics next week when I go back over...YES that's the Nova in the garage that has had been put on hold because of life in general..Enjoy yourselves now.......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Zap, I might be coming through on Wed, where do you want me to drop the beam.Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:I will only give you a little bit of crap, you should have mitered the joint as opposed to the straight 90 where you butter the sections up. Then again it is only a passenger vehicle not a MackDisclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:[QUOTE=tnjind;2861581]Funny how nobody is questioning this repair considering it is going on the road, but God forbid someone wants to build a small trailer............. I was thinking the same thing, wondering when the criticism would start.  However anyone who's been around here a while knows zap's workmanship and skill level and wouldn't question the quality of any project he sets his mind to doing.  Would like to see the pics , personally I probably wouldn't attempt such a project unless it was worth the trouble to take the body off the frame, getting too old to crawl around under vehicles getting burnt.  lol ."The reason we are here is that we are not all there"SA 200Idealarc TM 300 300MM 200MM 25130a SpoolgunPrecision Tig 375Invertec V350 ProSC-32 CS 12 Wire FeederOxweld/Purox O/AArcAirHypertherm Powermax 85LN25
Reply:Originally Posted by TozziWeldingZap, I might be coming through on Wed, where do you want me to drop the beam.
Reply:If that ain't "S&M welding" I don't know what is! Looks good, thanks for posting.
Reply:Here in Oklahoma you have to change the title on something like this.  I believe it's considered a "salvage" vehicle once you start major surgery.  I forget the particulars, but it does alter titling requirements.  It's supposed to be a heads up to future buyers."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Awsome fit up, complimented with booger welds  I know its getting plated tho so good job. Samm is right as well, better than what was there, but a hassle if he ever had to sell it. Just undercoat the snot out of it and trade it in. Shhhhh! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by farmersammHere in Oklahoma you have to change the title on something like this.  I believe it's considered a "salvage" vehicle once you start major surgery.  I forget the particulars, but it does alter titling requirements.  It's supposed to be a heads up to future buyers.
Reply:Originally Posted by weldermikeAwsome fit up, complimented with booger welds
Reply:Originally Posted by tadawsonI also don't buy into the "don't put in more than it's worth" argument - I think that comes from folks who sell cars.  I look at two things: Will it still meet my needs?Is it cheaper than replacement?IE $5000 to repair a $3000 truck vs replacement at $50,000 . . . to me, the choice is obvious.- Tim
Reply:Originally Posted by tackitNice job,  I can't get over how straight the cut is, I hate cutting steel with my reciprocating saw. Zap what brand of blade did you use and how many teeth. thanks
Reply:Originally Posted by zapster. . .There is not one spot of rust anywhere on the body..I took a real good look around under it everywhere this AM and it's absolutely PERFECT!Except for the frame where we replaced it.. . .He is going to put it all back together this week and next Saturday it's going for a full sandblast underneeth and chassis paint. . . .
Reply:Originally Posted by denrep--------------------------------Great fix. Thanks for the pics. But this one ain't gonna get the "fun jobs" line.
Reply:Zap, won't question the fit up or the technique but could you have picked a hotter, stickier time of year to dive into this project. would not have wanted to be the guy under the truck grinding away these last 2 days. LOL Just bought a Mohawk car lift , if I can figure how to fit it in my garage it will be great for this stuff."Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400
Reply:Originally Posted by kolotZap, won't question the fit up or the technique but could you have picked a hotter, stickier time of year to dive into this project. would not have wanted to be the guy under the truck grinding away these last 2 days. LOL Just bought a Mohawk car lift , if I can figure how to fit it in my garage it will be great for this stuff.