Cracked Chassis

[dlrogers]

Well, wouldn't you know it - had the car back on the road a few months and now Garage has found a crack in the chassis and wont warrant it until professionally repaired. The engine has to come out because we can't get at the chassis to weld a stirrup in. I have a manual but would appreciate any tricks of the trade being shared before I get into it  - do's and don'ts would be much appreciated.

[brads70]

Got any pictures? Wondering exactly were the crack is? On the K-frame? Frame rail?

[dutch]

my guess it`s cracked around the threadholes for the K-memberbolts in the framerails..?

[dlrogers]

Yeah, under K Frame (I think where it bolts through) but it is in a couple of places and almost all the way round. I'll get some pics. I'm really gutted. I thought I may be able to remove the fender but I think there is still the engine compartment bodywork to get past.

[dutch]

those spiderweb-like cracks are metal fatigue.  my cuda had the same problem. I made the cracks bigger with a dremel tool and welded them with a rod welder since there was a bunch of of grease and other contamination inside the rail. If you weld it mig, it will keep blowing out.
The cracks you talk about are bigger than the ones on my car and I`d advice you to weld an additional cap around the rail. If you decide to do so, don`t weld it top to bottom, just front to rear and maybe some extra buttwelds here & there.  Welding top to bottom across the rail will create a potential crack line.

[dlrogers]

Thanks Dutch - that sounds right on the mark. Over here in NZ, once a problem like this is recorded on the national database it has to have a certified repair under specification from an engineer. We don't seem to have the fredom you guys have. Just FYI, our cars over 5 years old have to have a "Warrant of Fitness" check every six months. If the vehicle passes the WoF, that info is recorded on the national database or conversely if it fails, that too is recorded. Every vehicle in NZ has to have a current registration also, and this is only able to be obtained if the vehicle has a current WoF. They have us by the B@!!s.

[brads70]

Sounds like a money grab( Taxes), and to create jobs.... Stupid you can't just fix it then have it inspected again?

[dutch]

we have them checks too.  cars over 3 years old every year,  over 25 years old every 2 years and pre 1960 cars not at all....     I`m not sure what would happen if they were to find a cracked framerail when checking a car...  I think it will be up to the engineer who does the check.
anyways, be glad the crack was found... you would look pretty stupid in your shiny 2 piece ride 
good luck

[dlrogers]

I've just found out this was a reasonably common fault on the Aussie assembled Valiants and that there was a repair part available as a sleeve - anyone heard of such a thing for the e bodies?

[dodj]

cars over 5 years old have to have a "Warrant of Fitness" check every six months.

Every 6 months!?! Geeez!! I agree with Brad, must be a government 'make work' project. What's the fee for a bi-anual inspection?
There are sleeves or caps made for e-bodies but I don't remember the name of the place. I saw them in a Mopar mag. I'll post the name later if I can find it.

[brads70]

There are sleeves or caps made for e-bodies but I don't remember the name of the place. I saw them in a Mopar mag. I'll post the name later if I can find it.

Is this the place you were thinking?
http://www.autorust.com/

[dodj]

Is this the place you were thinking?
http://www.autorust.com/

Ya, that's it. Thanks Brad. dlrogers, I have no personal experience with the place though. I don't know if their stuff is good quality or not.

[autoxcuda]

Yeah, under K Frame (I think where it bolts through) but it is in a couple of places and almost all the way round. I'll get some pics. I'm really gutted. I thought I may be able to remove the fender but I think there is still the engine compartment bodywork to get past.

Found stress cracks like those in my Barracuda in 1998 on the rear bolt holes. Like 270 degrees around the holes! That car had/has no rust.  I had seen some cracks on the side of the frame prior. But couldn't seen under the K-frame until I did a k-frame swap.   

We welded the cracks and put a plate to cover a couple cracks that went up the sides. We welded the cracks then covered them.

I've put a good 30K HARD miles on it since then. 

[wagesofsin]

bummer!!!
if you were in the states and able to get it to me , id fix it for free, and warranty for life , and i mean the life of people on earth!!!

best of luck.

[dlrogers]

That's terrific thanks everyone. Yeah, if I lived in the States I wouldn't have to jump though the hoops we are made to jump through over here. I guess they have good intentions but the bureaucrats always win! Thanks for the link Brad / dodj