Frame rust repair by steering box

Old August 31st, 2013, 12:48 PM
  #1  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Frame rust repair by steering box

Car is a 67 Cutlass Supreme convertible. I was working on the engine compartment, stripping down the frame and painting it. I saw what looked like a couple small rust spots where the steering box is bolted to the frame. I took the steering box off, drilled out that spot and tried to fix it with my TIG welder. It bubbled and had some porosity. I drilled out that stuff and welded that spot, and when that other area got hot I got more porosity, and after repeating things a few more times I figured out I'm pulling in rust and oil from the inside and needed to dig deeper. I found some extra holes on the bottom where the sway bar bolts in and cut a hole to see what was really inside. What I thought was 2 small spots was the tip of the iceberg. I think I have cut out enough to be down to good metal close enough to the original 1/8" thickness. Later I'll be tweaking angle iron to match the way this part of the frame was pressed when it was made.
seanm12 is offline  
Old August 31st, 2013, 12:53 PM
  #2  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Pics 1


Last edited by seanm12; August 31st, 2013 at 12:58 PM.
seanm12 is offline  
Old August 31st, 2013, 12:53 PM
  #3  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Pics 2

seanm12 is offline  
Old August 31st, 2013, 12:54 PM
  #4  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Pics 3

seanm12 is offline  
Old August 31st, 2013, 12:58 PM
  #5  
Registered User
 
Join Date: Jun 2009
Location: San Jose, CA
Posts: 3,928
Ya got some fuzz growing from somewhere there....



LOL!

But seriously though...nice work. It's amazing how rust can hide on ya.
svnt442 is offline  
Old August 31st, 2013, 01:51 PM
  #6  
Connoisseur d'Junque
 
MDchanic's Avatar
 
Join Date: Sep 2010
Location: The Hudson Valley
Posts: 21,180
Wow. That ain't too pretty at all.

Should be fine after welding up with good metal, though.

- Eric
MDchanic is offline  
Old September 1st, 2013, 06:37 AM
  #7  
Registered User
 
Join Date: Mar 2008
Posts: 3,467
Check elsewhere on the frame for rust!
Run to Rund is offline  
Old September 1st, 2013, 03:25 PM
  #8  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
svnt442 (Randy) - Thanks for the funny response! I got a good chuckle.
Run to Rund - Yep, will check for more frame rust, starting with the other side where the sway bar bolts to the frame. Fabricating the pieces to replace what I've cut out will take a lot of time as most of what I cut out was pressed with a lot of bends. I'll post more pics as I move along with that fabricating.
seanm12 is offline  
Old October 6th, 2013, 04:59 PM
  #9  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Frame repair part 2

OK, got most of the repair done, and time to post some pictures. I took a lot and will post them 5 at a time. I wanted to share what I figured out as I went through this repair since I get plenty of info from other folk's posts. Here's some comments for all of the pictures:

1. I started by cutting out 1 part, then another, then another. That's the old rusty parts tack welded back together to show what I needed to replace.
2. After a bunch of cardboard templates that's what I created from 1.5" x 2" angle iron after a bunch of cutting and bending. The bottom of the frame is about 3" wide so 2 2" wide angle iron gave me a good starting point to lap weld instead of butt weld.
3. Sorry the tack weld pictures are fuzzy. I was pretty tired then.
4. The picture with 3 parts if from making one twice. The 1st one (middle) ended up being too small. A whole bunch of crazy bends!
5. How I figured out where to drill the hole for the 3rd bolt. I used washers to space the particleboard over the round steering box.
6. I got a piece of gas pipe from the hardware store for the tube that goes between the bolt holes.
Attached Images

Last edited by seanm12; October 6th, 2013 at 05:09 PM. Reason: Typo fix
seanm12 is offline  
Old October 6th, 2013, 05:00 PM
  #10  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Frame repair part 3

Pics part 3
Attached Images
seanm12 is offline  
Old October 6th, 2013, 05:02 PM
  #11  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Frame repair part 4

Pics part 4
Attached Images
seanm12 is offline  
Old October 6th, 2013, 05:03 PM
  #12  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Frame repair part 5

Pics part 5
Attached Images
seanm12 is offline  
Old October 6th, 2013, 05:05 PM
  #13  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Frame repair part 6

Pics part 6
Attached Images
seanm12 is offline  
Old October 6th, 2013, 05:06 PM
  #14  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Frame repair part 7

Pics part 7
Attached Images
seanm12 is offline  
Old October 6th, 2013, 05:08 PM
  #15  
Registered User
Thread Starter
 
Join Date: Jul 2012
Location: Marengo, Illinois
Posts: 105
Frame repair part 8

Pics part 8. The end!
The welds were done by TIG. That's the 1 welding machine I have.
Next to drill and tap holes for the stabilizer bar!
Then may get back to painting this dagom frame!
Attached Images
seanm12 is offline  
Old October 6th, 2013, 06:11 PM
  #16  
Connoisseur d'Junque
 
MDchanic's Avatar
 
Join Date: Sep 2010
Location: The Hudson Valley
Posts: 21,180
Nice work! I'm impressed.

You may want to weld in nuts for the sway bar bushings, as the original threaded holes occasionally strip out.

- Eric
MDchanic is offline  
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
easytobedead
Paint
2
April 10th, 2009 06:16 PM
lshlsh2
Body work
8
March 4th, 2009 03:27 PM
Frankenpez
Cutlass
8
February 2nd, 2009 07:03 PM
scott_442
Chassis/Body/Frame
8
December 12th, 2008 07:57 PM
nosrevle
Cutlass
1
March 18th, 2006 01:24 PM


Thread Tools
Search this Thread
Quick Reply: Frame rust repair by steering box


Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.