Need help Steering box Frame= not good.

[cmpayne]

Hello all,
I need some help and maybe some of you can. I have a 87 K5 blazer and it pulled the steering box through the frame and ripped it. What would be the best way to fix it or is it past repair? Hopefully the pics will help.

[thirsty]

There is a plate made for that area.
That looks pretty rough though. Maybe a welder should take a look at it.

[bd]

OUCH!!!

Anything can be done if you have the time, money and resources.  Your biggest repair issue in this case is that the cracks radiate along/through the rail radii and propagate completely across the width of the flanges.  The radii and flanges provide the structural integrity, strength and torsional stability to the frame.  The plate Thirsty refers to is designed to address star burst and tear-out around and between the bolt holes; they aren't quite large enough to adequately correct a failure that has progressed as far as yours has.  You'll need to fabricate your own plates.

Jig and clamp the broken frame back into its original shape and position; drill, weld and dress all the cracks so the frame assumes its original shape, appearance and thickness; then fabricate custom 3/16"-thick plates for the outboard and inboard faces and both upper and lower flanges.  You could add additional strategic support between the flanges inside the frame.  The problem with doing this is that it makes that section of the frame extremely rigid and concentrates stress in adjoining parts of the frame, predominately just aft of the existing failure; so you could develop additional cracking with hard use. 

Because of the strain imparted to a 4x4 gearbox-to-frame mounting, any repair solution will require additional bracing to prevent the gear from tin-canning the frame again in the future.

Take a look at the linked thread to get some ideas and adapt it to your situation...
http://forum.73-87chevytrucks.com/smforum/index.php/topic,23828.0.html

[cmpayne]

Thank you for the help.

[bake74]

     As what bd said, only thing I would add is this is not a repair that should be done from a person who only has welded at home as a hobby.  You need structural welds, unless you are a professional welder I would consider taking it somewhere or find someone who can come to you.

[cmpayne]

As of right now its looking like I may have to scrap the truck. No shop in my area will touch it. And I can't weld nor will I try on something like this.

[bake74]

As of right now its looking like I may have to scrap the truck. No shop in my area will touch it. And I can't weld nor will I try on something like this.

     Try looking for a replacement frame.  Where are you located ?

[thirsty]

As of right now its looking like I may have to scrap the truck. No shop in my area will touch it. And I can't weld nor will I try on something like this.

     Try looking for a replacement frame.  Where are you located ?

I agree. If your truck is good other than that then replace the frame instead of scrapping it.

[cmpayne]

I do happen to have another frame but it needs some minor welding as well, two cuts in middle of it and body mounts need some repair. But I know I can't weld for one I never welded so I know I can't do it and two I don't have a welder or a 220 outlet to plug one into. Bake74 I'm located in imperial Missouri. To be honest I don't think I can scrap it, it just might be sitting for a very long time. Thanks for the help and input.

[nitewolf]

You can get a 110 welder. thats what I use and sense I don't have a shop to work in I just have to use flux core wire so I don't have the extra cost of gas.

[Edahall]

As of right now its looking like I may have to scrap the truck. No shop in my area will touch it. And I can't weld nor will I try on something like this.

I faced the same situation as you on my 1982 Suburban.  This is definitely very shade tree but I ended repairing mine with some very thick straight grain hardwood.  I cut the hardwood to fit inside the frame and bridge across the crack.  I then used Bondo to fill any voids between the hardwood and frame.  Afterwards, I used lag bolts to attach the steering box back to the frame.  The repair was a success and has lasted thousands of miles without issue.

[thirsty]

I cut the hardwood to fit inside the frame and bridge across the crack.  I then used Bondo to fill any voids between the hardwood and frame.  Afterwards, I used lag bolts to attach the steering box back to the frame.

Please don't do this.

If you can't swap frames then maybe look into a certified welder that can repair it. Over the road trucks, dumps, and all sorts of trucks have their frame dimensions changed more than you would think. This can be repaired, you just have to find the right guy.

[bd]

I cut the hardwood to fit inside the frame and bridge across the crack.  I then used Bondo to fill any voids between the hardwood and frame.  Afterwards, I used lag bolts to attach the steering box back to the frame.

Please don't do this.

If you can't swap frames then maybe look into a certified welder that can repair it. Over the road trucks, dumps, and all sorts of trucks have their frame dimensions changed more than you would think. This can be repaired, you just have to find the right guy.

x1000
Approaching a frame repair in this manner endangers everyone!

[bake74]

You can get a 110 welder. thats what I use and sense I don't have a shop to work in I just have to use flux core wire so I don't have the extra cost of gas.

     Also do not do this.  A 110v welder is not for frames.  It's duty cycle and penetration capabilities is not enough to do a frame.  I can understand no one wanting to touch your frame with the bad steering box rip, but the second frame you have does not sound that bad.  If you strip it and take it somewhere I bet they will weld it up for you, and this time have a weld in brace for the steering box welded in place and save yourself some headaches down the road.

[Blazin]

No 110 welders, no flux core crap wire, and NO WOOD OR BODY FILLER in your frame.
 
We shorten, and stretch big rigs, and trailers all the time. You don't have to go to a welding shop. Most likely they are going to say no because of the liability. They are probably very capable of repairing that, but if for some reason you were to get in a wreck, hurt or kill someone friend or stranger, and the frame had been repaired. It would be there but in the sling! There are plenty of capable guys that do hobby welding that could fix that frame, or section in a piece from another frame.
If it were me I would section in a new / used piece. That way you only have to remove the LH inner fender.
One more thing before repairing that frame look it over with a fine tooth comb. Is it worth repairing? You might find other problems with it. Then it would be better to swap your drive train, suspension, and or body onto another frame.