Aluminum trailer frame repair

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Got a rather nasty job in today. Here's some pics of what I'm dealing with. Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:More picsMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:and more. Including some nice looking welding (not).Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:All I've got for now. more as the story unfolds.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Not certain I would risk the liability exposure as there is bound to be a lot you can't see which could be your fault for not fixing in the courts. Hope not however.SlobPurveyor of intimate unparalleled knowledge of nothing about everything.Oh yeah, also an unabashed internet "Troll" too.....
Reply:That's nasty! Are you gona fix it?
Reply:Wow - that frame really did not like having that unit bolted like that If I'm looking right, there was no effort made to spread out the load those bolts were holding?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:That is real ugly! Isn't that one crack through the main frame flange too? That's going to take some serious engineering to get thst right! I look forward to watching this project progress. I hope you will have time to post pics as you go.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:Originally Posted by SlobNot certain I would risk the liability exposure as there is bound to be a lot you can't see which could be your fault for not fixing in the courts. Hope not however.
Reply:Originally Posted by welderjThat is real ugly! Isn't that one crack through the main frame flange too? That's going to take some serious engineering to get thst right! I look forward to watching this project progress. I hope you will have time to post pics as you go.
Reply:Originally Posted by irish fixit  Yeah it's a mess. I'm still trying to figure out why it pulled outward so hard on the frame. They have it bolted on 4 corners and braced diagonally though I believe they did the diagonals opposite of the way I think best. It's cracked there before at the flange and been welded on the top side (I'm still trying to figure out how they did that weld since It's almost impossible to see much less get a welder in there). At some point in time somebody added the second angle iron to help spread the load on the heavy corner but it wasn't anywhere near enough. I think the biggest problem is that it needed a plate on the inside to spread the load over a larger area than four small thing washers.
Reply:Originally Posted by MinnesotaDaveI think you're right - no plating has to be the wrong way to do it.Shouldn't it also be braced between the frames near the attachment points?
Reply:Sunds like a good plan - sure a lot better than the first attempt 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:Wow! I want good pictures. I can't guess how you'd weld those cracks. I'm guessing this involves replacing lots of material.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:Is that a live bottom trailer or a tanker of some sort? I would love to see some pics from further back to see more of an overall view.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:Originally Posted by Willie BWow! I want good pictures. I can't guess how you'd weld those cracks. I'm guessing this involves replacing lots of material.
Reply:Is there any cracking around the top of the trailer box? I'm just wondering if part of your problem is from the trailer twisting. That crack in the flange is what makes me question it since that is a bit off from the other damage. Either could be the cause, but if the trailer is twisting the repair will likely need to be handled differently. Is the frame underneath steel?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:At first I thought you were dealing with a pneumatic trailer.  If it's rounding the radius in the frame, it would put that trailer out of service. In the web, that should be fixable with some plates and welding.
Reply:Originally Posted by welderjIs there any cracking around the top of the trailer box? I'm just wondering if part of your problem is from the trailer twisting. That crack in the flange is what makes me question it since that is a bit off from the other damage. Either could be the cause, but if the trailer is twisting the repair will likely need to be handled differently. Is the frame underneath steel?
Reply:Ok here's the promised pics.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:MoreMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:This one and the last one in the last post are the two cracks I was talking about in the front of the trailer earlier. This is fairly normal and to be expected in a location like this. Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:I'm with you in that the frame doesn't do much for carrying the trailer, I suspect it's more there to carry that unloading mechanism. I'll look forward to your repair.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:Lol first thing to do is make them drag that nasty wagon through a truck wash!     so far the repairs are looking spot onVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Ok. It took a while what with the weather and other interruptions. I'm not happy with all of it especially the aluminum welding. It fought me the whole way but I finally got it to where I think it's got a chance of holding.  As you can see I added the fish plate to the outside. Just no way to get a acceptable weld inside with the room available. It was hard enough as it was.    Inside I put a piece of 1/2" aluminum plate as large as I could fit in there. I used this as a backing plate to make a full penetration weld to the frame from the outside. I also plug welded all the holes that where in the frame to this plate.  The other mounting points I made these backup plates to help spread the load. I painted them and the back of the mounting plate near the engine with cold galvanized to help slow the corrosion issue.   Here's another view of the mess. Notice that I moved the fuel tank back to make room for the fish plate. I also added another diagonal to the legs to help stiffen them up. Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htmIt's much better than it was. Those old truck bodies are hard to weld, it's like the oxidation goes all the way through. Nice job!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:Looks good to me I'm sure a truck like this gets beat on - so when another area breaks they'll be back 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:Originally Posted by irish fixitThis one and the last one in the last post are the two cracks I was talking about in the front of the trailer earlier. This is fairly normal and to be expected in a location like this. Attachment 1070341
Reply:Your repairs look better than the rest of the truck.  That APU is just to heavy to mount on a frame that wasn't meant for that loading.  It would have been lots cheaper to go the conventional way and put a wet kit on the tractor in the first place.
Reply:Originally Posted by welderjIt's much better than it was. Those old truck bodies are hard to weld, it's like the oxidation goes all the way through. Nice job!