I have finally welded up the damaged body mount holes.
As the others say measure measure measure.
One I could measure pretty easily.
The other was trickier due to the bow in the frame.
I ended up using a piece of string and two punches. (what tricks do you have?)

After some ugly welding on one the other came out pretty well.
Grinding down the ugly one took a little work but not terrible for a rookie like me.




some ugly welding here


Grinding cleaned up ok



Grinding



Nice tight fit

Measuring with the string helped






Not much grinding required here

cleaned up pretty good

 

Tap the new weld area with a dead blow to make sure the weld got good penetration.
Once you are done welding and grinding be sure to paint inside the frame under the weld spots. Consider Eastwood's internal frame coating.
Good measure to have the frame checked at a frame shop to make sure its straight before final finish and body mounting. This trick insures a good start on getting good panel gaps. Crooked foundation makes a crooked car.

https://www.eastwood.com/eastwood-in...z-aerosol.html

 

The metal on couple mounts holes is very thin, I am thinking to weld the washers underneath.
There is access to get them in place and considering of plug welding them in place.
I can't imagine the bolts being too short with the washer thickness.

Any reason not to do this repair?

Thanks

Tim

 

Well....I by no means mean to be a debbie downer here but if the frame is that bad I would search out a dry rust free frame. Think about all the work you are going to put into the frame AND the car only to find the frame begins to crack after your restoration. I'd hate for that to happen to you. Just throwing it out there.

I've never seen washers welded to the underside. Difficult to grind flush. The frame to body bolts may not have enough thread engagement on the cage nut?.

 

Decided to do two more where the frame holes were kinda thin.
My welding is kinda like my golf game hit or miss at any point.

 

Looks good! My golf is the same way lol.

how did you enlarge the hole to fit the washer?

 

looks good at least you can perfect your welding skills on an area nobody will see anyway

 

The first two I used a Dremel cutoff blade and then a grinding stone.
Took almost 8 - 10 hrs cutting prepping and welding.

The second I used Eastwood Reciprocating pneumatic metal saw
To rough in the holes then started with the Dremel grinding stone.
I ended up switching back to the air saw for the finish cut.
The air saw made short work of it probably under 2 hrs including final grinding.
that's with 15-30 minutes wasted with the grinding stone.

 

i have an IR airsaw its a good tool. I used it to cut out my floors. no sparks and less noise and mess than the cutoff wheel

For the dremel I really havent had a lot of luck w the stones (at least not in the timeframe i had in mind)
but i bought a metal cutting burr tool and that thing can do some damage. Its helped me out a couple times making slotted holes

heres link to a similar one

I was just curious as to how you were rounding them out, im always looking to learn something new !