Gazzar Posted February 25, 2018 Share Posted February 25, 2018 I've been working on the chassis today, and the front axle chassis bush holder is cracked in the chassis rail. What's the best approach to repairing this? Current plan is to cut out the crack and shoulder up with weld, but is there a better plan? Quote Link to comment Share on other sites More sharing options...
lo-fi Posted February 25, 2018 Share Posted February 25, 2018 Give these guys a shout, they make chassis parts and may be able to sell you a new tube: http://www.ddsmetal.co.uk I've bought brackets for swb rears, so I know they have a supply of correct size tubes, or possibly roll their own. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted February 26, 2018 Author Share Posted February 26, 2018 Thanks, but the tube is mostly fine, it's the zone around the weld on the chassis rail where the cracking is happening. I've been thinking about this and I've had a change of mind. I think I'm going to open the chassis rail and weld in a 6mm triangular fillet in each corner internally. Between the tube and the chassis, if you get me. I think what is happening is the bush wants to rotate, transmitting this to the chassis hence the cracking. A big chunk of steel extending out the chassis should dissipate the stress over a bigger area. I think. I'd love to plate the inside of the chassis as well, but that may be over kill. G. Quote Link to comment Share on other sites More sharing options...
Jon White Posted February 26, 2018 Share Posted February 26, 2018 I’ve had exactly this. I just welded the cracks up. jon Quote Link to comment Share on other sites More sharing options...
Gazzar Posted February 27, 2018 Author Share Posted February 27, 2018 Yes, I'll do that. The stress is spread over about 4 inches each side. If I weld up along side the old weld, that spreads it over 5 inches. I don't think that's enough, so I'll also do some internal bracing, so the stress is over more inches. Thanks, G. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted March 1, 2018 Author Share Posted March 1, 2018 I tried something different tonight: I wired up the crack, then ground all flush. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted March 1, 2018 Author Share Posted March 1, 2018 Then I removed the bottom from the rail. I picked some off cuts, these are 5mm thick. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted March 1, 2018 Author Share Posted March 1, 2018 And welded them in, hot, lots of amps and several passes. Not very clean in there, so the weld isn't pretty. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted March 1, 2018 Author Share Posted March 1, 2018 Pop another brace on the tube, and cap the lot. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted March 1, 2018 Author Share Posted March 1, 2018 That won't crack again. Or, if it does, I've bigger problems! Quote Link to comment Share on other sites More sharing options...
Gazzar Posted March 2, 2018 Author Share Posted March 2, 2018 And repeat. Quote Link to comment Share on other sites More sharing options...
jordan_meakin Posted March 4, 2018 Share Posted March 4, 2018 Nice work. Seeing inside like that, it's understandable why they go rotten. Quote Link to comment Share on other sites More sharing options...
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