I cut out and patch substantial rust damage on the unibody frame of my 95 Saturn. This is immediately behind one of the front wheels. The car was undercoated…
DIY Unibody Frame Patching – Major rust holes, car or truck frame – repair, welding, fixing
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My brother showed me how easy it is to stick weld and we tacked on mild
steel just to cover up the damage. Then we sprayed with some under coat
black rubber based paint. It makes it look like shit but it really hides it
to the point of you can’t really tell if there was any welding done. I was
going to take the truck to be finally inspected but as I left my driveway,
the pressure hose for the steering wheel blew and so I have to get a new
one of those now.
so what happened? im interested to know because im in welding school we we
have welded mild steel pipe to stainless pipe with no problems using
stainless filler rod. we used steel filler rod and it welded but the back
side was a mess, the only thing we change when switching from mild steel to
SS was filler rod so im interested to know what was going on with your set
up
I just want everyone to know that that rust converter stuff works okay on
suface rust, but if you are painting something that isn’t rusted like in
the video it won’t adhere properly because a chemical reaction between the
rust and paint must take place before it dries. also once it dries a
chemical reaction with the rust cannot take place so it is very poor rust
protection for non rusted steel.
i need to know of there are any places that make custom unibody rails
because mine is rotted off of my 1960 chrysler saratoga
My brother is helping me out. He pointed out the rule of if they can’t see
it, they can’t fail it so. Hey maybe ill get my camera and make a video of
how he is doing it.
The welding part I find the easiest and quickest (too quick for all the
prep I have to do). Prepping it such as cleaning it takes a while. I have
watched a bunch of tig welding videos here on youtube so I do know what the
beeding should look like (and have an artistic tallent so I think that
helps), and bought the miller table chart, thickness ruler and have the
millermatic 150. So I am set to go. My brother just started helping this
past weekend showing some tricks and how easy stick welding is
in NY they’d spot the diamond plate…but if you use flat metal with
undercoat they’ll never know…depends on the shop too…I had a kid pass
my car and it had a huge gaping hole right next to the shock mount…
That’s what I thought. But I guess it depends on the State (?). In PA it
wouldn’t fly and I don’t think NY either.
This repair passed inspection? I thought it was a big no-no to weld patches
on an auto frame – I bought an old truck one time where the frame had been
welded.. wound up giving it to a guy for a field truck because I couldn’t
get it inspected.
Welding stainless takes a real pro with all the right gear – and besides
it’s nearly impossible to weld dissimilar metals with any success. I’m not
a SS expert by any means but I know some grades are brittle and therefore
not suitable for structural members in vehicles, buildings, etc.
Nice job. You get an “A”
Stainless steel! Why use stainless steel? I think you may have a problem
with trying to weld that metal.I know nothing about tig but with mig
welding and gas brazing you need special supplies to weld or braze stainles
steel. you better get some regular steel and weld it in with your tig.
Don’t use stainless because it may not be possible to weld stainless to non
stainless steel.unless you braze it but that is a frame. I think you have
to remake the metal with the original type steel, sorry.
What type of metal did you use? I just tried to tig weld 1/8 stainless
steel to my 93 nissian truck frame. the stainless steel was beading but the
frame was not even melting. I tried to concentrate more on the frame and I
could see I was starting to blow a hole through it and it wouldn’t really
melt just enough to bead. I am really starting to feel demoralized about
this because it took me weekend to measure, prep the metal, shape it, and
clean it from any impurities. Please someone help.
Dam dude good job
Looks like termite damage. LOL
what made you decide to use thick diamond plate instead of buying the right
sheet metal? free spare metal i guess… well it does the job! welds look
good 🙂
lol and it makes one strong jack point with the thick plate
wouldn’t cause you to fail inspection?
Where do you even find pieces of metal like that to use? I have the same
rust problem that I’m trying to work on.
Yeah, I know it is overkill but I like the whole mad max look. My grandma
always said you can never have enough diamond plate. That section is a
common rust spot so I figured I would make it strong! 🙂
Uhh this is on the frame of the car not the sides of it if you put “Sheet”
medal on the frame it will probably collapse like a pop can.
I think but something on the rust before the repair would be a idea to stop
it not just cover it.
you have a lifter in your home garage? you’re so bad. Not everyone has that
humongous help.
Thanks for the video. I have a 1995 Saturn SW1 with rust damage right where
the unibody bolts to the subframe. Do you think a similar patch could be
fabricated for that location without taking the subframe off?
That’s not even bad mines horrible
Hi, how do you protect the weld from the inside, where the paint can’t
reach?
You might be able to if you drop that corner of the subframe to gain
access. I have found it difficult to patch things that are hard to reach.
Perhaps it is just my welding skills aren’t goo enough work in awkard
places. Good luck!