Using improper welding techniques causes many weld and/or frame failures. The following information points out potential areas of difficulty and provides general guidelines for successful frame welding:
| • | Most weld failures occur at the end of the weld in areas of the frame under high stress. |
| • | Eliminate the ends of the weld by making a hole or slot in the part to be attached . |
| • | Use a fillet weld around the slot or plug weld. |
| • | Do not leave a notch at the end of a weld. |
Do not overweld, especially areas of the frame that receive high concentrations of stress.
Weld small cracks in a crossmember. Refer to Repairing Cracks Description .
Perform the following steps when welding:
- Disconnect the battery.
- The frame is covered with a protective wax coating.
- Do not use oxyacetylene welding equipment.
- Use electrodes with a smaller diameter.
- Only use as much heat as is necessary to achieve adequate penetration.
- Make sure that the weld is free from craters and undercuts.
- Remove the scale from each successive pass.
- Grind the surface of the weld flush with the parent material when repairing a crack.
- Do not weld across the flanges when mounting any accessories.
- Do not weld within 19 mm (0.75 in) of a flange when mounting any accessories.
- Leave at least 6 mm (0.23 in) between the end of a weld and the edge of the part.
- Do not weld the cast brackets to the frame.
- Do not weld together the flanges of any cracked reinforcements and base rails.
- Do not attach the ground cable to the engine. Connect the welding machine ground cables as close to the working area as possible.
- Keep the welding cables away from the vehicle wiring. Avoid any 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.
| - | Use a wire brush to remove any concentration of wax before welding. |
| - | Apply a new wax coating when done welding. |
Make several passes. Do not make any more passes than necessary.
