Subframe repair

admin

Hi this is my first thread and I'm only a beginner fabricator so cut me a lil slack. It all started out when a friend of mine brought a subframe to me to be modified. Instead of using stock mounts the frame needs plates welded in so a hockey puck can lay flat on and have maximum surface area to hold on to.  Here you can see that the front of the frame is in good shape but the rear is pretty rusty on the sway bar mounts, but especially on the two rear subframe mount points. So onto rust repair. The next two pix i put a 16ga sheet metal under the surface and welded it in. And then i took a couple little pieces and used them as filler metal to get a flat surface. The filler pieces welded in and everything brought up to stock height.And then ground smooth
Reply:Onto the front, in this picture the bottom plate has been partially welded in and the washer tacked in place. You can see the hole i made. Right after i realized i was running too hot. after the top washer is welded in and ground flat ready for the top plate.Top plates welded in Left sideRight side
Reply:NiceDavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Second pic down..Not much of a wheel left .. ...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:Originally Posted by zapster Second pic down..Not much of a wheel left .. ...zap!
Reply:Originally Posted by zapster Second pic down..Not much of a wheel left .. ...zap!
Reply:Thanks the wheel had to be that small because its the only way to cut out that small of a piece. Lol i ended up runing out of small wheels and had to "grind down" a 4in wheel to 3in  The frame isnt finished yet because i still have to reinforce the rear thas where the real problem is. As you can see in the photos is really corroded down to no metal almost. I'm gonna bend 3/16" plate to fit in the rear and post pix once done. OOOOH btw is that too many pix i wasnt sure. If it is i can convert them to links.
Reply:Originally Posted by operdotOOOOH btw is that too many pix i wasnt sure.
Reply:I notice you are using a magnet ground clamp.  I have bought one but not hooked it up.  Do you like it enough to chuck the conventional spring clamp??
Reply:Its prety nice. I'm using a cheapo HF one and after i got done welding the last pieces it was a little warm to the touch even though it was nowhere near any heat which means there was a bit too much current running through it. I definetly wouldnt recomend it for any welding done above 150 amps. But i'm sure there are magnetic clamps that are rated for that. THe magnetic clamp is really nice when you dont have an edge to clamp on a regular spring clamp? I would buy some extra cord and use both clamps. I have made extension cords out of some 2awg cable and 7 dinse connectors. Just havent made a cord for the spring clamp yet. Also i need to make control cables for the miller 17 and 14. Got the connectors waiting on the cable.
Reply:Does that patch piece look like stainless steel to anybody else?
Reply:Originally Posted by 76GMC1500Does that patch piece look like stainless steel to anybody else?
Reply:That may cause some problems.
Reply:Just my opinion i perfer to use the aluminum oxide grinding disk seem to get more life out of them cheaper and eat less grit I usally use 24 grit on a 4 1/2 inch grinder local stores like lowes and home depot sell them for $1.40 a disc some times you can get time from industrial supply places such as travers tool company or msc supply for .60 to .70 cents disc if you buy a pack of 25 but well worth it good for sanding grinding and cleaning rusty steel I would recomend the dewalt backing bad for these pads for a 7/8 arbormillermatic 210syncrowave 180 SDhypertherm 380craftsman buzzboxclarke drill press/bandsaw
Reply:I usualy buy the longest life 7" disk i can find. I've been using really thin disk for making cuts and thicker ones for grinding. I'm really not a fan of the "backing pad" it seems to small and can't take down enough in one pass. On the matter of the type of steel. Its 16GA mild steel on the plate. The reason it looks like stainess is because i turned up argon to 27cfm because i was welding outside and the wind kept messing with my beads. But since we are on the subject whats the problem with ataching stainless steel to mild steel?
Reply:If you use the wrong filler, the welds crack.
Reply:Hey nice work! Thanks for sharing with us.... We like to see how others approach different repairs and thats how we all learn from each other.... So NO, you didn't post too many pictures, there are never too many picturesHowever I need to point out since your new to the Forum.************************************************** ******Websters defines Fabricator as follows "CONSTRUCT, MANUFACTURE; specifically : to construct from diverse and "usually standardized parts ************************************************** ******This was not construction however, it was a repair so you are a "Repairicator"not a "fabricator".One other thing I don't see any dimes in your post ....Perhaps ZAP can lend you one?  See attached photo ... (I took the liberty of retouching it for you)Alright,alright,sorry. .. ... just messin with you .... Thanks for sharing and again nice work!Washman Attached Images
Reply:i have had good results by using a carbon block gehind the area to be filled/repaired. The carbon acts as a heat sink as well as a weld-resistant surface to allow build-up of edges, or filling of gaps without burn-through. Copper blocks work for this as well but the carbon is much easier to shape to fit irregular surfaces.I obtained several cylindrical chunks of carbon from a metal scrapyard. The look like a giant piece of pencil lead, about 3" in diameter, and they can be shaped with a pocket knife or rasp.
Reply:Looks good man, cant wait to see the rest of it..Various GrindersVictor Journeyman torch200cf Acet. 250cf oxygenLincoln 175 plus/alpha2 gunLincoln v205t tigLincoln 350mpEsab 650 plasmaWhen you can get up in the morning, Its a good day.Live each day like its your last.
Reply:Hi sorry that it took me this long to post a reply but i've been busy with school finals. Anyways i finished the job a week or two ago. I fabricated the rear brackets to repair the rotted away part of the frame and welded those in place. Also i made a strut rod bushing mount out of 3/4 metal its in the wise in the first pic. Anyways enjoy.
Reply:Looks like your having fun.. Ambitious is good!Keep it up......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.