1967 Chevelle frame repair - Chevelle Tech
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post #1 of 10 (permalink) Old Sep 3rd, 19, 2:25 PM Thread Starter
 
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1967 Chevelle frame repair

I'm stripped my '67 down to the frame and found that 2 of the front body mount pockets are rotting out. I'm going to have the frame blasted and powder coated but need to fix this first. Looking for suggestions on the proper way to repair this. See the attached photo.
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post #2 of 10 (permalink) Old Sep 3rd, 19, 2:45 PM
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Re: 1967 Chevelle frame repair

This is actually a pretty easy fix. Someone sells thick flat washers with the correct ID size for the bushing to sit in.

You'll need to open up the area of the damage to the proper OD of the washer & weld it flush. Once it's ground & painted, nobody will ever know it was repaired.
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post #3 of 10 (permalink) Old Sep 3rd, 19, 4:08 PM
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Re: 1967 Chevelle frame repair

Fastenal sells the same washers for about a third of the price that some of the Chevelle suppliers, forgot the part numbers may need to do a little searching.
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post #4 of 10 (permalink) Old Sep 3rd, 19, 6:36 PM Thread Starter
 
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Re: 1967 Chevelle frame repair

Thanks everyone!! I found the washer you suggested. Should be able to get that fixed quick and easy.
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post #5 of 10 (permalink) Old Sep 3rd, 19, 9:15 PM
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Re: 1967 Chevelle frame repair

Most pros and hobbyists stock metal and don't need to buy repair kits. If subbing it out to a welder, they would have steel in stock. I make my own patches like many do in the restoration industry.
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post #6 of 10 (permalink) Old Sep 3rd, 19, 9:22 PM
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Re: 1967 Chevelle frame repair

Quote:
Originally Posted by Mikes64 View Post
Fastenal sells the same washers for about a third of the price that some of the Chevelle suppliers, forgot the part numbers may need to do a little searching.
Shops and non pros buy steel directly and pay less than a middle man charges.
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post #7 of 10 (permalink) Old Sep 3rd, 19, 9:28 PM
 
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Re: 1967 Chevelle frame repair

Folks are right, you can buy the specific washer inserts from UMI, or flat washers from the hardware store will work. I use both, depending upon the severity of surrounding rust and metal thickness. If the rust is serious around the hole, I have machined the larger hardware store washers to correct I.D. and whatever O.D I need to fully clear the rust.

Generally, it's pretty simple/quick.

I use a hole saw on a pneumatic drill. An electric or cordless drill will work, but they generally struggle on metal holes this size.

Weld a tab across the damaged hole, and take your time to locate the original center as best as possible. Drill a small pilot hole, and then go for it with the hole saw.

Below are some pictures. One is a smaller O.D. UMI washer (they laser cut them) and the other is a larger hardware store washer. I use a 2 3/8" hole saw for the UMI. I make the O.D. of the hardware store washers not only clear the rust, but accommodate a common hole saw size.

I weld them in with TIG, using about 95-100 amps. That seems to work the best for me to get full penetration without burning through. MAKE SURE THE METAL IS CLEAN BEFORE WELDING!

NOTE: the last thumbnail shows the underside of completed repair - it will look like it is not fully penetrated in the top of the picture. That is where the frame halves overlap from the assembly process, and the weld generally won't penetrate through both layers of frame material. You can see full penetration where it is only one layer of frame material.
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post #8 of 10 (permalink) Old Sep 6th, 19, 1:19 PM Thread Starter
 
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Re: 1967 Chevelle frame repair

Thanks everyone! I went ahead and got the washer from Fastenal since I just needed 2 ($5.31 total). It seems it will be way less time/work than fabbing these out from scratch. Thanks for the pics!!
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post #9 of 10 (permalink) Old Sep 7th, 19, 11:22 AM
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Re: 1967 Chevelle frame repair

Quote:
Originally Posted by Raven1 View Post
Shops and non pros buy steel directly and pay less than a middle man charges.
You are correct, however in rural areas ain’t so easy, only one “metal shop” here and they know it.

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post #10 of 10 (permalink) Old Sep 7th, 19, 5:02 PM
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Re: 1967 Chevelle frame repair

Quote:
Originally Posted by Bronze68 View Post
Weld a tab across the damaged hole, and take your time to locate the original center as best as possible. Drill a small pilot hole, and then go for it with the hole saw.
What a great trick - thanx for sharing!

Hole saws work great as long as you know how to use them; slow speeds, and using a cutting oil. They will stay sharp and cut through steel again and again.
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