Improper techniques cause many weld and/or frame failures.
Most weld failures occur at the end of the weld in high stress areas of the frame. Eliminating the ends of the weld will reduce frame or weld failure. Make a hole or a slot in the component to be attached. Use a fillet in order to weld around the slot or the plug. Do not leave a notch at the end of the weld.
Over-welding can be harmful, especially in areas of high stress.
When welding small cracks in a crossmember, use the following procedure:
- The frame is covered with a protective wax coating. Use a wire brush in order to remove any concentration of the wax before welding. Coat the area with new wax when the welding is complete.
- Do not use oxyacetylene welding equipment.
- Whenever possible, use smaller diameter electrodes. Make several passes with the electrodes.
- Do not use more heat than necessary in order to give good penetration.
- Ensure that the weld is free from craters and undercuts.
- Ensure that the scale is removed from each successive pass.
- When repairing a crack, grind the surface of the weld flush with the parent material.
- When mounting the accessories, do not weld across the flanges.
- When mounting the accessories, do not weld within 19 mm (0.75 in) of a flange.
- Do not weld to the edge of a component that is being welded to a frame. Leave 6 mm (0.25 in) between the end of the weld and the edge of the component.
- Do not weld the cast brackets to the frame.
- Do not weld the flanges of cracked reinforcements and the base rails together.
- Do not attach the ground cable to the engine. Connect the welding machine ground cables as close to the working area as possible.
- Disconnect the vehicle battery and the auxiliary battery, if equipped.
- Keep the welding cables away from the vehicle wiring. Avoid direct contact between the welding cables and any part of the vehicle.
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
