Posted by Bill B(2) on Wednesday, October 23, 2002 at 9:53PM :
I have a problem with the frame on one of my W100 trucks. It's a '63W100. I've owned it for thirty years, so I have a pretty good idea of what shape it's in. I live in the SE part of Pennsylvania so it has seen some winter weather which has contributed to the perpetual rusting of the sheet metal. The frame has shared the same fate, especially the left side. I found a small crack on both sides of the frame at the kick-up part over the rear axles about ten years ago. I welded up the crack and welded a plate over the repair. I have not seen a problem since. My next concern is that the frame rails are getting close to rusting through at several points along the left side under the bed. It is really bad from the rear axle out to the end of the rail. I have a class three trailer hitch bolted to the frame. Please excuse my long winded explanation of the truck. I wanted everyone to know the history of my truck in case someone has a better idea for solving my problem.
After thinking about the problem, I have come up with a possible fix based on my ability to do it. I am considering getting some 2" by 4" square tubing and fitting it to the inside of the rails with bolts. I know it won't go in without cutting and fitting. I can use a hole saw to cut holes at certain points for access to the wiring, brake line and the bolts needed to secure it to the original frame. Since the inside dimension of the frame is less than four inches, I will have to slit the tubing down the middle, cut out the some of the center, then weld it back together.
The kick up for the axle will be a little bit trickier. I can either miter the tubing and weld it together, or try my luck at bending the tubing after I've slit it, then weld it together. I have a 30 ton shop press at home to work with.
I will clean up the frame as best I can(sand blast it?), and apply undercoating. The new "tube frame" will be undercoated on the side that will be against the original frame before being bolted in place. The reason I want to bolt in the tube frame is that I don't want to do extensive welding on the original frame for fear of ruining it with the heat. Another reason for bolting it in place is, if it doesn't work out or a better method presents itself in the future, I can take it all back out.
After it's in place, I will undercoat the rest of it, run the wires back inside, and re-install the brake line.
One of my concerns is with water getting trapped in the tubing and not being able to drain out. To help with this I am wondering if I should make sure that the access holes go all the way to the bottom of the tube to allow the water to run out. Does this sound right?
Further up the frame rail in front of the axle, the frame opens up to a little less than six inches. I will use 6" tubing at that point. It looks like I can stop at the cab. The frame looks OK from there.
Does this sound like a reasonable solution? I have all the tools,machines, and welders to do this so my only cost will be the material. I don't feel that the work is over my head. I have been working on all of my stuff for over thirty years(I can't believe I'm that old!), and I did all my own work on my race car for a few years.
My question is, does this look like a sound strategy? Any and all comments are welcome.
Bill
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