LLY: Frame Welding

[valleyduramax]

I have a few drilled holes that I need to fill or plug that are 1/2" diameter. They are from my first version of the front traction bar mounts that I made up quick last summer but decided to remake it this week. It is a crossmember style mount with side plates that well bolt to just behind the rear cab mount on my reg cab long box.

I need these holes filled as they are in the area of where new holes will be drilled. I was gonna cut out some round plugs from some flat stock and then spot weld till totally welded in on both sides of frame then grind the weld flat. Would this be ok and will it cause any cracking issues?

 

[Schwinn68]

If you could find some flat brass you could use that as a backer and just weld the entire hole shut. The weld doesn't stick to the brass

 

[countrycorey]

Aluminum would work as well

 

[valleyduramax]

So just fill the hole with weld instead of making a plug? I good with either just thought the plug would match up better with the frame material?? I just don't want issues in future with cracks since that is where the traction bar forces will be induced into the frame. Probably over thinking it lol

 

[Josh2002cc]

The frame is welded from the factory...you will be fine. I have replaced and welded in many frame sections and never had an issue with any of them. Enjoy your project.

 

[Schwinn68]

If you have concerns with that section you could always box it in or put a fisheye patch over it.

 

[Chris611]

If you need the holes, then re-use them. If not, I would just leave them. Welding them shut will potentially cause more issues than leaving them. The additional stresses added from welding them shut will be more detrimental than just leaving them.

Later.

 

[Porno Joe]

If you need the holes, then re-use them. If not, I would just leave them. Welding them shut will potentially cause more issues than leaving them. The additional stresses added from welding them shut will be more detrimental than just leaving them.

Later.

Could you explain this to me? I'm not understanding how welding holes shut would be bad?

To the OP, honestly for a 1/2" hole you could prolly just tack weld around the hole until filled in then grind smooth

 

[Chris611]

Could you explain this to me? I'm not understanding how welding holes shut would be bad?

To the OP, honestly for a 1/2" hole you could prolly just tack weld around the hole until filled in then grind smooth

When you weld a hole shut, the welding process creates a heat affected zone (HAZ). This is because the weld process creates 2500-3000 deg F temps in the weld zone. This creates a localized "hard" area where the weld is done vs. the relatively "soft" area of the base material. If you did a post heat treat to anneal the welded area back to the same hardness as the original material, it would be okay. Generally, that is not done. The area between the "soft" and "hard" area is the HAZ. That is where cracks usually start.

I don't think a 1/2" hole in the frame has near the potential of creating a crack vs. the HAZ of welding the hole shut.

 

[Ne-max]

When you weld a hole shut, the welding process creates a heat affected zone (HAZ). This is because the weld process creates 2500-3000 deg F temps in the weld zone. This creates a localized "hard" area where the weld is done vs. the relatively "soft" area of the base material. If you did a post heat treat to anneal the welded area back to the same hardness as the original material, it would be okay. Generally, that is not done. The area between the "soft" and "hard" area is the HAZ. That is where cracks usually start.

I don't think a 1/2" hole in the frame has near the potential of creating a crack vs. the HAZ of welding the hole shut.

X2

 

[jlawles2]

I would be a bit on the cautious side for welding on the frame. Some of the newer trucks use high strength alloys that have yield stresses in the 100,000 psi range.

Also the molten weld metal will shrink as it cools causing internal stress in the area where the filler metal and the base metal meet.

 

[Ne-max]

I cut my frame in half to shorten it and rewelded it. It is holding up great so far. But I do agree that the heat weakens it. On our work trucks it has stickers all over the frame saying do not weld to cause of that reason. Personally just leave the holes.

 

[arneson]

When you weld a hole shut, the welding process creates a heat affected zone (HAZ). This is because the weld process creates 2500-3000 deg F temps in the weld zone. This creates a localized "hard" area where the weld is done vs. the relatively "soft" area of the base material. If you did a post heat treat to anneal the welded area back to the same hardness as the original material, it would be okay. Generally, that is not done. The area between the "soft" and "hard" area is the HAZ. That is where cracks usually start.

I don't think a 1/2" hole in the frame has near the potential of creating a crack vs. the HAZ of welding the hole shut.

X3!!!!!!

 

[Porno Joe]

When you weld a hole shut, the welding process creates a heat affected zone (HAZ). This is because the weld process creates 2500-3000 deg F temps in the weld zone. This creates a localized "hard" area where the weld is done vs. the relatively "soft" area of the base material. If you did a post heat treat to anneal the welded area back to the same hardness as the original material, it would be okay. Generally, that is not done. The area between the "soft" and "hard" area is the HAZ. That is where cracks usually start.

I don't think a 1/2" hole in the frame has near the potential of creating a crack vs. the HAZ of welding the hole shut.

Ok I knew about the welded vs non. Just wanted some clarification.

I guess my thinking was- has frame cracking EVER been an issue on a dmax?

 

[valleyduramax]

I should have been more specific in the sense that the holes are exactly where the new ones need to go but close enough that it well make a slot once I drill the new ones. This is the only reason that I would like to fill the old holes. A buddy helped with the install of the original and it was basically a rush job the night before a pull and the brackets went in not square to each other and now the new one is perfectly square and gonna cause me some headaches to install because of the existing holes.

 

[Chris611]

I think you are maybe over-thinking it. Most of the stuff we do/add to our trucks are probably not the best for longevity. I'd say just make it work however you need to. Fill-it & drill-it or slot it. Chances are you won't ever have a problem with it either way. It won't fail all at once. If you are worried, just keep an eye on the area. If you see cracks starting, then you will have to address it.

 

[valleyduramax]

Ya I have a tendency to do that sometimes lol. Ill try plugging the hole and go from there. Thanks for the responses

 

[OregonDMAX]

if you are making traction bar mounts and the old holes are in the way you need to find a mount that you can weld directly to the frame instead of drilling more holes and bolting another mount on.