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#220140 - 03/03/06 01:39 AM STICKY: Frame repair. How I Did it  
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tmos87 Offline
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Canton TWP MI
This is how I fixed those rotted body mounts on the frame. This process applies to all the mount locations but for times sake I'll just show the one.

The rotted hole after wire wheel


The 3" Flat washer with some alignment marks


A little hammering and the washer starts to conform




Then trace and cut the hole


Tack the washer into place



#220141 - 03/03/06 01:54 AM Re: Frame repair. How I Did it  
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benwa Offline
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Very nice.

That's how mad87 was descirbing it wasn't he?

I like that idea looks like it works great.



(My sig courtesy of sickspeedmonte)
Check out all my rides/projects at:
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#220142 - 03/03/06 02:03 AM Re: Frame repair. How I Did it  
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tmos87 Offline
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Canton TWP MI
Part 2.
finish weld all around the washer
Good penatration is criticlal


Dress the weld


Punch the hole


Finished hole.


Like I said before this process was done on four of my mount locations. I have some pics of the others also. I missed a couple pics in the steps but used pics of the opposite side to fill in the blanks. I'm happy with the results and the strength of the repair. Thanks to Mad87SS for the washer idea. the washers I used were the same thickness as the frame steel. Looking forward to paint next week. If all goes as planned I'll have more progress pics next week. Tom

#220143 - 03/03/06 02:06 AM Re: Frame repair. How I Did it  
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Mack Offline
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Looks great! Thanks for the pics.


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Greg
LY6 6.0L with 4L80 trans
8.5 w/3:73s
http://www.fquick.com/87SS
#220144 - 03/03/06 03:21 AM Re: Frame repair. How I Did it  
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mrapii Offline
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A great post and a terrific job. These are the kind of posts that give us real useful knowledge.

#220145 - 03/03/06 04:19 AM Re: Frame repair. How I Did it  
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nitelite Offline
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Tampa, FL
Awesome Tom!!


Scott - '85 SS, t-tops, grey bucket/console, all power, posi, and currently in midst of frame-off rebuild.
#220146 - 03/03/06 12:51 PM Re: Frame repair. How I Did it  
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1984 MonteManiac Offline
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tax york
Yes, this will help me on my GTO resto I may have one body mount to repair.... I know I have some to do on the monte....



I hate know it alls and doubting toms.
#220147 - 03/03/06 01:12 PM Re: Frame repair. How I Did it  
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SickSpeedMonte Offline
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MD
Very nice work. You cant even tell there was a repair done, and thats the way to go!

I am not familiar with that punch... Im guessing you just crank down on the bolt and it cuts the hole out for you?

#220148 - 03/03/06 01:29 PM Re: Frame repair. How I Did it  
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runupfront Offline
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Eatonton, GA
Really impressive work - repaired the way it should be repaired.

Super welding job too - I know I can't weld like that!

I think the pics and step-by-step should go into a tech article here on the board.


Pete Scuderi
1986 AeroCoupe
#220149 - 03/03/06 04:59 PM Re: Frame repair. How I Did it  
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benwa Offline
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Monaville, WV
Yep great tech article on a how to frame repair.

I'm wondering though is THAT many body mount holes were bad lol

WHAT was holding the body?????????

I truelly understand now why you needed a frame off resto. Good job on not crushing it because of that problem.

I mean I just wonder when body mounts are that bad doesn't the body flop up and down by itself and you can like grab it and lift up on it?



(My sig courtesy of sickspeedmonte)
Check out all my rides/projects at:
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#220150 - 03/03/06 06:26 PM Re: Frame repair. How I Did it  
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Duts87SS Offline
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Outstanding work!!!


Dustin
87 SS
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#220151 - 03/03/06 06:54 PM Re: Frame repair. How I Did it  
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Mack Offline
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Hillsborough,NJ
I just had to look at those pictures again, great work! I can only hope my repair comes close to your outcome. I did have a couple of questions.

1. I too would like to know what that tool was you were using to enlarge the hole.

2. What did you use to cut the holes in the frame? I figured a cutoff tool would be too large, maybe a dremel? That could take some time.

3. How did you weld the washers in, tack weld like welding body panels skipping around until the entire washer is welded in or did you run 1 bead all the way around the washer?

Thanks, and again great work. I agree, put this in the tech section.


[Linked Image]
Greg
LY6 6.0L with 4L80 trans
8.5 w/3:73s
http://www.fquick.com/87SS
#220152 - 03/04/06 06:31 AM Re: Frame repair. How I Did it  
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tmos87 Offline
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Well thanks a lot guys, glad you like the pics. been a busy day. So I'm a little late getting back to the board.
Mack. The punch I used is a Greenlee punch, used by electricians for punching holes in electrical boxes. sizes for 1/2" and up. the largest I have used is a 5". I used a 1 1/4", it's just a little bit larger than the original hole. Just keep tightening the bolt and it draws the cutter through the metal. The ones I use at work are hydrolic and much easyer to use. They leave a nice burr free, perfectly round hole.
I welded continuous bead from tack to tack. And since I ground the weld smooth, I turned the heat up kind of high for penatration. Looking at it from the bottom I can see that I got full pen. and won't ever have to worry about failure of the weld.
Thanks again for the responces. This board is just a great place to be. Tom

#220153 - 03/04/06 10:42 AM Re: Frame repair. How I Did it  
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Gruvin Offline
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Glad all that info is on here and archived now since soo many of us have frame rot issues. This is a truely outstanding idea...


My first SS! Sold Jan 2004
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87 SS bought 9-5-04: Sold 6-18-2010 - project 87 finds a new home with another undisclosed MonteCarloSS.com member!
#220154 - 04/10/06 10:29 PM Re: Frame repair. How I Did it  
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irkk1 Offline
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A+ effort what a job ! HMMM I hope ill be able to do that ...

#220155 - 05/02/06 04:44 PM Re: Frame repair. How I Did it  
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NY03SS Offline
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Nice job on the repair. I will definitely bookmark this page for future reference. Out of curiosity, what gauge wire did you use in your welder? If I have to do this I want to make sure I get full heat penetration to ensure a sturdy weld.
Thanks!!


Later,

Bri
#220156 - 05/02/06 06:21 PM Re: Frame repair. How I Did it  
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tmos87 Offline
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The wire is linchon .030" I set to a heavy medium high amperage and a medium speed on the feed. Wow. I'm a poet. Anyway I got full penetration and needn't worry about weld failure. Make sure to coat the under side of the weld as well.
And thank all of you for the compliments.

Tom

#550261 - 03/27/08 07:24 PM Re: Frame repair. How I Did it [Re: tmos87]  
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bladerunnerss Offline
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Beautiful, very professional. you should etch "repaired with pride in the U.S.A. by Tom" in there somewhere.

#550490 - 03/28/08 03:45 AM Re: Frame repair. How I Did it [Re: bladerunnerss]  
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ss4ever Offline
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WOW, old topic back from the deal.

Tom, this would make for a wonderful DIY writeup!


1983 Monte Carlo SS Turnkey ZZ4/700R4, Dakota Digital Instrument Cluster, 77k mile car. Many more mods to come soon.
#550578 - 03/28/08 02:28 PM Re: Frame repair. How I Did it [Re: ss4ever]  
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SS Ninja Offline
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 Originally Posted By: ss4ever
WOW, old topic back from the deal.



Yeah it is! I saw a post from Anthony and had to double-check the date! Anybody heard from the Maniac recently?


1987 Monte Carlo SS: The toy
Click here for my build thread
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#550579 - 03/28/08 02:42 PM Re: Frame repair. How I Did it [Re: SS Ninja]  
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85_SS Offline
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I'd be the guilty party - I remembered it a week or so back and made it a sticky. I agree - it would make a great DIY writeup!


[Linked Image]
1985 Chevrolet Monte Carlo SS
5.7 LITRE / TES Headers / SShaker Hood / WC T-5 5-Speed
1970 Pontiac GTO
Orbit Orange Judge Re-creation / YZ RAIII 400 / M21 4-Speed
#550706 - 03/28/08 09:43 PM Re: Frame repair. How I Did it [Re: ss4ever]  
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tmos87 Offline
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 Originally Posted By: ss4ever
WOW, old topic back from the dead.

Tom, this would make for a wonderful DIY writeup!


Thanks guys. Let me get the quarter panel project done, and I'll do a better write up for the DIY forum.

Tom

#552739 - 04/03/08 03:47 PM Re: Frame repair. How I Did it [Re: tmos87]  
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valvefloat ss Offline
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St.Joseph, MI
Great work! Great discussion. I will need this eventually.

Does anyone know what kind of steel is used for frames? 1030, 1040, ASTM???


1985 SS, 358 010, art carr 700r4, Comp Xtreme 4x4 cam, 50SeriesFlows,Afterburner headers, ported SR Torquers, 750 3310 Holley, Auburn Posi, 3.73, 3in exhaust, dual electic fans.
#554354 - 04/07/08 09:09 PM Re: Frame repair. How I Did it [Re: valvefloat ss]  
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Sure the holes 1 1/4" ? and not 1 1/2"?

Duke

#556805 - 04/14/08 02:26 AM Re: Frame repair. How I Did it [Re: dukeofbluz]  
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tmos87 Offline
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Canton TWP MI
 Originally Posted By: dukeofbluz
Sure the holes 1 1/4" ? and not 1 1/2"?

Duke


The GreenLee punches I use are for electrical work, meaning 1-1/4" I,D.(Pipe fitting) the actual hole is about 1-1/2" for the O.D.

Tom

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