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Front side frame rust repair
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Posted 11/9/2014 4:02 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
Front side frame rust repair

This is one spot I currently have on my 300GD and which is present on more 460 G's.

Passenger side frame rail, front section.
The end-plate which is welded on here, is partially rusted away, same for the front round cross member (rusted through).

It will mean some cutting and welding in the front section of this frame rail, to also reconstruct this round crossmember.

Question up front:
- On the inner side of the framerail, there is some sort of collar visible (see red arrow). Is that part of the framerail of the crossmember? In other words, should I cut at approx. the red line of directly at the framerails?

gr. Bram



Edited by bram_r 4/17/2016 4:30 PM




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#224961
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Posted 11/9/2014 8:57 PM
Atl-Wagen
Member




Date registered: Sep 2014
Location: Atlanta, Georgia
Vehicle(s): 80's something w460-230ge 2013 Honda Ridgeline
Posts: 47
25
RE: Front side frame rust repair

I hope this saves you a trip to the hardware store when it becomes time to put the front bumper back on...



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#224969 - in reply to #224961
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Posted 4/17/2016 4:32 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
Re: Front side frame rust repair

Uploaded some new pics, didn't fix it last year; anybody here did such a framerepair before?

gr. Bram
#232133 - in reply to #224961
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Author
Posted 4/22/2016 12:38 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
RE: Front side frame rust repair

Here we go;
- pic 1: cut the tube and the collar/weld between the frame rails and created a gap.

- pic 2: cut the weld/collar on the outside too and after some final grinding and hammering, the tube section came out.

- pic 3: here the tube section is: diameter 90mm, wall thickness 4mm.

- pic 4: after removal of this tube section, I saw some kind of baffle a little up in the framerails. Don't know why it's there, but I thought share the observation.





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#232164 - in reply to #224961
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Author
Posted 4/24/2016 3:47 PM
Fernando BR



Date registered: Jan 2007
Location: Brasil
Vehicle(s): G500/05 300GE/91 300GD/80
1000
Re: Front side frame rust repair

Near home.

http://www.ebay.de/itm/Mercedes-G-Klasse-W460-W461-Rahmen-Reperatur...
#232179 - in reply to #224961
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Posted 4/25/2016 1:09 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
Re: Front side frame rust repair

Fernando BR - 4/24/2016 9:47 PM

Near home.

http://www.ebay.de/itm/Mercedes-G-Klasse-W460-W461-Rahmen-Reperatur...



Thanks for the link Fernando!

But I think the pipe in this add is for the front body mounts (behind front wheels) and also rear shock mounts (diameter 70mm, wall thickness 4mm / 70x4mm).
For this front section 90x4mm pipe is required.

Not to worry however. A friend of mine rolled his G and tomorrow I can cut up his chassis getting me the correct pipe.

Gr. Bram

Edited by bram_r 4/25/2016 1:52 PM
#232189 - in reply to #232179
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Author
Posted 4/25/2016 10:45 PM
hipine



Date registered: Jul 2006
Location: US, CO, Bailey
Vehicle(s): 460 1980 280GE w. 617A
5000
RE: Front side frame rust repair

Nice work Bram! Thanks for sharing the pix.

-Dave G.
#232194 - in reply to #224961
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Posted 4/25/2016 10:52 PM
oskar
Elite Veteran


Date registered: Sep 2006
Location: Lyons, CO
Vehicle(s): 1981 280GE, 2002 G500, 280SE 4.5, Audi A4 1.8T
Posts: 708
500
RE: Front side frame rust repair

just FYI:

here is where I buy my steel, especially for bodywork I needed the DC01 type ....
They have seamless round tube 70x4, 90x4 , for example

http://www.metricmetal.com

Oskar

Edited by oskar 4/25/2016 10:57 PM
#232195 - in reply to #232194
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Author
Posted 4/26/2016 5:29 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
RE: Front side frame rust repair

Found my repair section from a rolled swb 300GD.

Probably only going to weld in a new tube section and restore that front plate:



Gr. Bram



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#232203 - in reply to #224961
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Posted 4/27/2016 4:55 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
RE: Front side frame rust repair

Upon some closer inspection and some poking I decided spot repairing the front section is not viable, too many bad spots, rust has gone quite far here. The driver side frame rail is perfectly fine btw...

So I'm replacing the front passenger side corner section.
After double/triple measuring, time to cut in my chassis!

Looking into the cut off frame rail of my chassis, luckily everything looks fine.
So the rust was contained in that front section and will be replaced with a more solid front piece.

The new corner section is ready to be welded in. More next time I have some time for that step.

gr. bram





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#232210 - in reply to #224961
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Posted 4/27/2016 5:30 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
2000
Re: Front side frame rust repair

If you can find some correct size box steel and tube to fit snugly inside the repair sections, you can pre-drill some large holes in both outer joined pieces and weld additional reinforcements through the frame member. I'm not sure if I am being clear, but some of the frame tube joining is done this way in Graz.
I will look for a picture.

Edited by otiswesty 4/27/2016 6:03 PM
#232211 - in reply to #232203
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Posted 4/27/2016 6:05 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
Re: Front side frame rust repair

otiswesty - 4/27/2016 11:30 PM

If you can find some correct size box steel and tube to fit inside the repair sections, you can pre-drill some large holes in both outer joined pieces and weld additional reinforcements through the frame member. I'm not sure if I am being clear, but some of the frame tube joining is done this way in Graz.
I will look for a picture.


I know what you mean.

The modifications you describe is used for lengthening frames especially.
This section I'm doing does not get a huge weight or moment on it, so I think I can repair this with just welding the new section against the existing frame.

If I were to lenghten the frame between front and rear exle or extend the rear section for a big pick up, I would do the overlap welding.

gr. bram
#232212 - in reply to #232211
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Posted 4/27/2016 6:05 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
2000
RE: Front side frame rust repair

In this gusseted military spec frame, you can see the seam at the center of the rear frame tube with 15 mm holes to either side. The seam is welded all around and the frame holes are fully welded through to the inner pipe as well.



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#232213 - in reply to #224961
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Posted 4/28/2016 4:06 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
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Re: Front side frame rust repair

Interesting! Probably reinforced for increased towing weights or something like that.

The original design is already pretty strong with that large 90x4mm tube, but not strong enough for this application.
#232220 - in reply to #232213
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Posted 4/28/2016 7:37 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3004
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RE: Front side frame rust repair

Here are a couple pics from a rear frame member section I have.



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(Holes.jpg)



(Pipe.jpg)



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#232228 - in reply to #224961
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Posted 4/29/2016 6:18 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
RE: Front side frame rust repair

Very nice to see the OEM details! Thanks for sharing.

Started this evening lining all the parts up, so that everything is correct up to the millimeter.
I got the frame section of the manual (31) to verify some measurements. See attachment for those interested.
I put a threaded bar through the front crossmember. With some clamps and steel bar I lined up the frame rails. Almost done and now thinking about the welding proces.

And while I'm at it, replace the donut style frame engine mounts to the trapeziodal ones.
Waiting for the last one, which is on back order:

Gr. Bram



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#232240 - in reply to #224961
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Posted 5/1/2016 1:42 PM
hipine



Date registered: Jul 2006
Location: US, CO, Bailey
Vehicle(s): 460 1980 280GE w. 617A
5000
RE: Front side frame rust repair

Great work Bram. Nice to "watch" a craftsman at his task. Thanks for sharing.

-Dave G.
#232252 - in reply to #232240
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Posted 6/10/2016 7:06 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
RE: Front side frame rust repair

Took some time before the last parts came in, but here we go:

I started with some practicing on the old section, which I clamped on the chassis to work out my welding in that position:

Once I was happy with the settings and position, time to prepare the welds with a 45 deg angle and of course clean all the metal from paint and wax layers:

See below for the finished result and some weld details.

gr. bram



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#232738 - in reply to #224961
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Posted 6/10/2016 7:14 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
RE: Front side frame rust repair

And for those interested in frame measurements and thickness of the sections:

Frame ladder: Height1=124mm, Height2=116,5mm, Widht=76mm, Wall thickness=3,5mm
Round crossmember : Diameter=90mm, Wall thickness=4mm






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#232739 - in reply to #224961
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Posted 6/11/2016 7:21 AM
Inkblotz
Expert




Date registered: Apr 2006
Location: Georgia
Vehicle(s): 90 300GD "Thundering Turtle II", w/ 603A turbo
Posts: 3186
2000
Re: Front side frame rust repair

nicely done Bram.

M
#232741 - in reply to #224961
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