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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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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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Very nice.

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

I like that idea looks like it works great.



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#220142 - 03/03/06 02:03 AM Re: Frame repair. How I Did it  
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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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Looks great! Thanks for the pics.


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#220144 - 03/03/06 03:21 AM Re: Frame repair. How I Did it  
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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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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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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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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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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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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?



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#220150 - 03/03/06 06:26 PM Re: Frame repair. How I Did it  
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Outstanding work!!!


Dustin
87 SS
#220151 - 03/03/06 06:54 PM Re: Frame repair. How I Did it  
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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.


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Greg
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http://www.fquick.com/87SS
#220152 - 03/04/06 06:31 AM Re: Frame repair. How I Did it  
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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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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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#220154 - 04/10/06 10:29 PM Re: Frame repair. How I Did it  
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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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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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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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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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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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 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
1987 Monte Carlo LS: Daily Driver
Build thread for the LS
#550579 - 03/28/08 02:42 PM Re: Frame repair. How I Did it [Re: SS Ninja]  
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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!


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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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 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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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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 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

#556825 - 04/14/08 03:02 AM Re: Frame repair. How I Did it [Re: tmos87]  
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Good to know for if I ever get to this stage - I believe we have 1" and 1.5" GreenLee punches at work \:\)


[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
#577208 - 06/14/08 09:52 PM Re: Frame repair. How I Did it [Re: tmos87]  
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looks great........


Derek - 327 SBC - SMCC member
#583615 - 07/04/08 12:31 AM Re: Frame repair. How I Did it [Re: POWEREDbyCHEVY]  
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you can grab the cheep hole knock pout punch at Hrabor freight for 15 bucks... I had to do pretty much 7 mount location they came ok. The two large mount holes were diffrent sizes. what girt did you use to knock down the welds grinding wheel or 2 inch abrasive disk?.. I did take pictures of mine some day i will put them up with the rest of them ..

#643319 - 01/30/09 12:29 AM Re: Frame repair. How I Did it [Re: irkk1]  
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I did pretty much the same repair but found a local bolt company that sold a washer with a 1.5" ID about a 2.25 OD and the washer was $1.25 instead of having to purchase the tools to cut the hole.


87 Monte,TPI conversion eng/trans from an 89 IROC had a paxton on it, its for sale! LS1 brakes and 9" rear finished, 3.56 with a locker to be tested. Been sitting since I graduated in 04 on the verge of resurrection. http://www.cardomain.com/ride/3192829
#655804 - 03/04/09 06:43 AM Re: Frame repair. How I Did it [Re: mymonte-ss]  
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can you re post those images? i would like to see your work and what the body mounts looked before and after you fixed them...



94 Thunderbird v8
#655891 - 03/04/09 03:46 PM Re: Frame repair. How I Did it [Re: ryzman]  
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what was the size of the washers used? O.D.

#701618 - 07/09/09 01:07 AM Re: Frame repair. How I Did it [Re: tmos87]  
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im tryin to put some 29.5 x 10.5 slicks under my monte and was wondering how i can notch the frame to get that tire under there without too much work

#727721 - 10/01/09 01:47 AM Re: Frame repair. How I Did it [Re: bbc86monte]  
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Great looking repair, good job. The only question I got is how did you locate the washer so that it will match the body?

#754561 - 01/07/10 06:13 AM Re: Frame repair. How I Did it [Re: DSMonteSS]  
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Originally Posted By: DSMonteSS
Great looking repair, good job. The only question I got is how did you locate the washer so that it will match the body?


x2

I am about to do this and want to make sure the hole is in the right place. Also where can I buy one of those green lee punch's?


'86 Monte carlo ss-Frame off resto-mod.
Ls2/t56/8.5"
#791993 - 05/07/10 09:47 PM Re: Frame repair. How I Did it [Re: Onebadbowtie86]  
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Jason, hold onto something secure, then check Ebay laugh
greenlee

#801577 - 06/11/10 01:34 PM Re: Frame repair. How I Did it [Re: rons87mcss]  
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craigslist too alot of electricians are getting rid of tools


88 SS. Got a 383 coming soon. No rear tires. Looks like a lion and it pulls like a fire ant!
#849481 - 01/25/11 01:39 AM Re: Frame repair. How I Did it [Re: DSMonteSS]  
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Originally Posted By: DSMonteSS
Great looking repair, good job. The only question I got is how did you locate the washer so that it will match the body?

X2 I've been wondering the same thing. And I am planning to do some repair of the rear 3ft of my Camino frame

#849521 - 01/25/11 04:40 AM Re: Frame repair. How I Did it [Re: nawlins-tim]  
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For this you need the correct ID on the washer. I went to a Catapillar Tractor dealer where they have very large, very hard washers. After looking through their parts stock they found washers for me. Not cheap - $5 or so apiece. Cut a hole that was the OD size of the washer and welded it in.




[Linked Image]

1988 MCSS T-Tops. Frame off restoration, 330HP 350 crate engine, 700R4 transmission.
#849522 - 01/25/11 04:43 AM Re: Frame repair. How I Did it [Re: MattsMonte]  
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Just another way to go


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1988 MCSS T-Tops. Frame off restoration, 330HP 350 crate engine, 700R4 transmission.
#858967 - 03/08/11 10:37 PM Re: Frame repair. How I Did it [Re: tmos87]  
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I'm going to do this same project this weekend it looks from the picture that you used a 1 1/6 knockout for the mount hole is this correct because if so I will take the washers I have to work and punch out the centers with a hydralic greenlee k.o. set we have. Disregard this I went back and read the whole post and got my answer really nice work. I gotta stop beung so damn lazy

Last edited by SKIDMARK; 03/08/11 10:47 PM.
#972585 - 05/23/13 04:42 AM Re: Frame repair. How I Did it [Re: tmos87]  
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Buick Runner Offline
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Both Gbodyparts and Kirban who sell repair washers state that besides welding the washers in, you can also just slide the washers in under a new bushing. While welding is probably the better way to go, just sliding them in saves the hassle of lifting the body off the frame completely which is a big job to tackle for most of us. Though it probably also depends on how bad the frame rot is too, if the rot is really bad you may have no choice but to weld.

As for the cause of this kind of rot, it's a design flaw of the OEM bushings that causes such rust damage. The OEM bushings have a metal insert molded into them. This metal insert seems to rust out before even the rubber starts to rot. I have seen OEM bushings that became hollow after the metal insets inside them had completely rusted away. Now when these bushing inserts rust out, they create rust dust that becomes trapped between the bushings and the frame, causing frame rust. So these stupid inserts molded into the stock bushings is the #1 reason they fall apart and causing frame rot. Aftermarket poly bushings seem to be sold poly, no metal inserts molded into them that can rot the frame, a better than OEM design. After discovering, it is probably a good idea for every G body car to have their body mounts replaced with poly or other non OEM bushing types.


SBC powered 1987 Regal with TES headers, ZZ4 intake, ZZ4 PROM chip, mini starter, THM2004R, 2500 stall converter, 2040 cam, CCC system, and 3.73 posi rear.

2008 ex NPS P71 Crown Victoria, cop motor, cop shocks, cop brakes.

Never argue with an idiot.
They will just drag you down to their level and beat you with experience.
#973153 - 05/29/13 07:01 AM Re: STICKY: Frame repair. How I Did it [Re: tmos87]  
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Buick Runner Offline
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Dharma station 1 the Hydra
Kirban Performance sells pre-made repair washers ready to install, 1 for $6 or 2 for $10. Despite being a site for Buicks, the washers will work on any G body.


http://www.kirbanperformance.com/product...29+%237309.html


Last edited by Buick Runner; 05/29/13 07:02 AM.

SBC powered 1987 Regal with TES headers, ZZ4 intake, ZZ4 PROM chip, mini starter, THM2004R, 2500 stall converter, 2040 cam, CCC system, and 3.73 posi rear.

2008 ex NPS P71 Crown Victoria, cop motor, cop shocks, cop brakes.

Never argue with an idiot.
They will just drag you down to their level and beat you with experience.
#988555 - 11/22/13 03:44 AM Re: STICKY: Frame repair. How I Did it [Re: tmos87]  
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hey guys, im getting ready to do somw work on mine, and when i get this far, i was also wondering how you properly locate the center of the welded in washer to make sure it is in the right location? PLEASE HELP!!!!

#1021429 - 03/23/15 03:29 PM Re: STICKY: Frame repair. How I Did it [Re: tmos87]  
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Hello all,

I like many in this thread are wondering how everyone successfully located the hole for the bushing.

I prefer to not guess because some of the holes are oblong and deformed. This all seems a little more crucial to me being Im going to try solid aluminum bushings with SC&C rubber isolator kit.

#1050163 - 04/20/17 02:26 AM Re: Frame repair. How I Did it [Re: tmos87]  
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great thread im getting ready to do mine this upcoming winter

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