Broke ....

csheatz · October 21, 2011

This is a Standard repair guide for New full frame vehicles.

Please keep in mind that frames are welded at the factory with Fanuc Robots using mig welders. Bust out the miller and metabo and fix it! Its a truck, not a damn NASA mars rover!

General Guidelines for Stress Relieving Distorted Frames

Hammering for stress relief should be performed using a relatively light hammer and a limited amount of heat (when applicable). The hammer is applied, gently, around the immediate buckle to induce the grains of the metal inside the component to be redistributed away from the buckle, thereby reducing the stress level. This action should take place when the component is under tension from the pulling bench fixture.
If the manufacturer permits the application of heat, a rosette torch tip should be used to spread out the flame and slowly warm-up the area around the buckle, to the temperature limit indicated by the manufacturer. Temperature crayons, paints or other indicators should be used to monitor the heat limit.

General Guidelines for Frame Repair

The frame must be aligned prior to beginning any repairs. If cross-members, brackets or other mounting hardware is being replaced on the frame, replace factory MIG welds with MIG welds. If the hardware is attached with rivets, use grade 5 or better bolts and nuts for replacement.
If a fatigue crack is being repaired, each end should be drilled out sufficiently to stop the crack from further propagation. Then the crack should be ground to a outward bevel of 45° on each side and MIG welded completely, using a backer plate to insure complete penetration.
Doublers or "fish plates" should then be welded to either the inside or outside of the vertical element of the frame and to the flanges. In addition, cracks that exist on internal or external reinforcements should be repaired separately.

General Guidelines for Frame Replacement (Partial or Sectioning)

After re-alignment of the frame, measure and scribe cut lines as recommended in the sectioning procedure. Cut off the damaged portion of the frame.
For a butt weld with a backer, measure the replacement frame, using the same cut line dimensions as on the damaged frame; then measure an adjacent line deducting sufficient material for a root gap (typically 3mm), prior to the final cut.
The weld backer should be fabricated from the cut off portion of the damaged frame, approximately 12-13mm wide, and cut into lengths convenient for fitting up to the existing rail. Tack weld the backer strips inside the existing rail prior to final trimming and fitting up of the new front frame horn.
Finally, weld continuously around the outside of the gap, with sufficient passes to insure complete penetration. Dress the finished weld and apply the appropriate anti-corrosion coatings prior to re-assembly.

mhenshaw · October 21, 2011

A very special kind of steel that is worth more than gold in your case

i asked a question.. not really in the mood to joke.

It just ordinary steel and can either be Arc or Mig welded. Once the piece is back in place the welder would spot weld it to keep it from moving again. Then he would run small sections of beads in different spots so it does not overheat the frame and make it weak. Welding different areas at time and letting the frame cool inbetween the weld passes will not damage the frame.

After your frame is welded the welds will be the strongest part of the frame. You will not be able to break the weld but that does not mean your frame is stronger than before. Since welds are stronger than the metal you are welding then the frame will break right next to the weld. Which is why it is so important to keep the frame from getting overheated so the metal does not get damaged.

bgdeer1 · October 21, 2011

A very special kind of steel that is worth more than gold in your case

i asked a question.. not really in the mood to joke.

It just ordinary steel and can either be Arc or Mig welded. Once the piece is back in place the welder would spot weld it to keep it from moving again. Then he would run small sections of beads in different spots so it does not overheat the frame and make it weak. Welding different areas at time and letting the frame cool inbetween the weld passes will not damage the frame.

After your frame is welded the welds will be the strongest part of the frame. You will not be able to break the weld but that does not mean your frame is stronger than before. Since welds are stronger than the metal you are welding then the frame will break right next to the weld. Which is why it is so important to keep the frame from getting overheated so the metal does not get damaged.

thank you. Its kind of annoying because my dad "heard" that you CANNOT weld on these frames... And now that he hears from me that you can weld on them hes like " no you cant, its not going to work"

So if you guys were me, welding is the way to go.?

csheatz · October 21, 2011

So if you guys were me, welding is the way to go.?

spankrz · October 22, 2011

weld it. if it were my truck, i would do it myself. run a short bead or two, let it sit for a while and cool, weld a few more, let it sit, ect. that will be a simple repair for any experienced welder. it looks like you have room for a triple pass on there too.

bgdeer1 · October 22, 2011

weld it. if it were my truck, i would do it myself. run a short bead or two, let it sit for a while and cool, weld a few more, let it sit, ect. that will be a simple repair for any experienced welder. it looks like you have room for a triple pass on there too.

Like I stated before.. id rather try to get it repaired at no cost.. gm rep is coming next week to check. If not then I will.consider welding it.

wavery · October 23, 2011

weld it. if it were my truck, i would do it myself. run a short bead or two, let it sit for a while and cool, weld a few more, let it sit, ect. that will be a simple repair for any experienced welder. it looks like you have room for a triple pass on there too.

Like I stated before.. id rather try to get it repaired at no cost.. gm rep is coming next week to check. If not then I will.consider welding it.

Replacing the frame is something that a GM Service Rep can't even authorize without getting approval from higher-up unless this is a commonly known fault (which I doubt). It doesn't matter who your friend knows, there is no chance in .........Detroit ....... That any rep is going to risk his job trying to get a repair like that through. GM would likely require that the old frame be shipped back for testing. A frame "Failure" like that would be an extremely rare thing that would cause a lot of engineering and legal questions.

Let your friends go through the motions...... just don't get your hopes up.

A certified welder in a frame shop should be able to mig weld that frame and reinforce it. You wouldn't believe some of the welding that goes on in some of these off-road racing trucks..... The problem is, when a shop does stuff like that, they risk being responsible if someone is injured or killed in a crash because the frame did not "Crumple" in the manner that it was designed to do. Even if that was not the reason for the injury, a good lawyer could make it look like it was. Most responsible shop owners won't do that these days. Who needs the grief.

The other issue is, when you go to sell the vehicle, you will need to disclose the repair to keep yourself out of trouble for the same reason.

Again..... if it were ME on MY truck....... I'd do it in a heart beat. I wouldn't do it for you or anyone else for any amount of $...... Sorta hypocritical huh!!!!

ChevyTech77 · October 24, 2011

Replacing the frame is something that a GM Service Rep can't even authorize without getting approval from higher-up unless this is a commonly known fault (which I doubt). It doesn't matter who your friend knows, there is no chance in .........Detroit ....... That any rep is going to risk his job trying to get a repair like that through. GM would likely require that the old frame be shipped back for testing. A frame "Failure" like that would be an extremely rare thing that would cause a lot of engineering and legal questions.

Complete and total b.s. Things have obviously changed sense you got out of the biz. A DMA can authorize that frame to be replaced with little more than a few digital pictures for future reference. Happens everyday with the HD frames that are cracking right behind the upper control mounts due to heavy loads induced from snow plowing.

Stevens03 · October 24, 2011

Complete and total b.s. Things have obviously changed sense you got out of the biz. A DMA can authorize that frame to be replaced with little more than a few digital pictures for future reference. Happens everyday with the HD frames that are cracking right behind the upper control mounts due to heavy loads induced from snow plowing.

Just say whats on your mind.... Don't hold back...

spankrz · October 24, 2011

weld it. if it were my truck, i would do it myself. run a short bead or two, let it sit for a while and cool, weld a few more, let it sit, ect. that will be a simple repair for any experienced welder. it looks like you have room for a triple pass on there too.

Like I stated before.. id rather try to get it repaired at no cost.. gm rep is coming next week to check. If not then I will.consider welding it.

if there was a chance that i could get a new frame for free, i would wait too don't get me wrong lol but if that falls through i would weld it before i payed for a frame job (frame job.... that sounds dirty)

wavery · October 24, 2011

Replacing the frame is something that a GM Service Rep can't even authorize without getting approval from higher-up unless this is a commonly known fault (which I doubt). It doesn't matter who your friend knows, there is no chance in .........Detroit ....... That any rep is going to risk his job trying to get a repair like that through. GM would likely require that the old frame be shipped back for testing. A frame "Failure" like that would be an extremely rare thing that would cause a lot of engineering and legal questions.

Complete and total b.s. Things have obviously changed sense you got out of the biz. A DMA can authorize that frame to be replaced with little more than a few digital pictures for future reference. Happens everyday with the HD frames that are cracking right behind the upper control mounts due to heavy loads induced from snow plowing.

Geez...... ..... don't have a hernia.......

That's why I stated, "unless this is a commonly known fault".

In the 25+ years that I was with GM, I can only recall having to replace 1 truck frame do to a defect. The factory had the old frame picked up for inspection because it was such a rare occurrence.......

If you are correct in your statement, "Happens everyday with the HD frames" (which I sincerely doubt).... then things certainly have changed and that's a real poor example of GM quality........ Having said that....... the OP's truck does not have a HD frame on his PU and I doubt very much that there is more than 1 or 2 a year replaced under warranty. Easy enough to check.

txab · October 24, 2011

DBK81 · October 24, 2011

Not to rain on the parade here, but it will be a cold cold day in hell before GM replaces that frame, find a good welder and quit wasting your time.

ChevyTech77 · October 24, 2011

Just say whats on your mind.... Don't hold back...

I'm mostly Italian, call it a detriment.

Geez...... ..... don't have a hernia.......

That's why I stated, "unless this is a commonly known fault".

In the 25+ years that I was with GM, I can only recall having to replace 1 truck frame do to a defect. The factory had the old frame picked up for inspection because it was such a rare occurrence.......

If you are correct in your statement, "Happens everyday with the HD frames" (which I sincerely doubt).... then things certainly have changed and that's a real poor example of GM quality........ Having said that....... the OP's truck does not have a HD frame on his PU and I doubt very much that there is more than 1 or 2 a year replaced under warranty. Easy enough to check.

I am not having a hernia but again, some things have changed sense you left. You wield your 25+ years with GM around like its a great shield of your ever knowing knowledge of GM vehicles, service departments and policies. I'm a bit more in depth than just being a service tech anymore and spent nearly 15 years in the biz before getting to where I am at now to tell you that your one experiance with this, is not how the business is handled now-a-days, that's all.

And yes, the HD frame thing is for real but is not due to poor quality. It is due to the frames being overloaded with huge snow plows and then smacking a curb or two.

wavery · October 24, 2011

You wield your 25+ years with GM around like its a great shield of your ever knowing knowledge of GM vehicles, service departments and policies. I'm a bit more in depth than just being a service tech anymore and spent nearly 15 years in the biz before getting to where I am at now to tell you that your one experiance with this, is not how the business is handled now-a-days, that's all.

And your point is????

Are you saying that my experience is irrelevant because I've been out of the business for nearly 12 years?

Are you saying that in your experienced opinion, GM will pick up the tab on replacing the OP's frame...... If so, I hope that you are right and I'm wrong.

Other than that, what's your issue here? I never said that your experience as a tech had no value or relevance on this or any other subject. I have little knowledge of current model technology and I will be the 1st to admit it. As far as GM warranty policy and dealership procedures......... I doubt much has changed much and I still associate with people that work for GM and a close friend owns a local Chevy dealership...... I have a lot of experience there and dismissing that out of hand is a little misguided IMO.