Offroad-Express

I have just discovered my chassis is cracked around the steering box of my 80. does anyone know the proper procedure for repairing this or is it just a case of removing box and welding up.

cheers jono

Pull the box off and blaze it up bro.

wopass wrote:Pull the box off and blaze it up bro.

Teenagers have a different meaning for blazing it up these days

So does Wop

it will be hard to get a plate in there as the crush tubes will stop anything from being push through the chassis section.

that said some nicely scribed 4mm plate drillout to suit the steering bolts etc and welded on would do the job nicely.....but...
check if it will need to be certed first. and the use of a hoist will definitely be of an advantage

mudlva wrote:it will be hard to get a plate in there as the crush tubes will stop anything from being push through the chassis section.

that said some nicely scribed 4mm plate drillout to suit the steering bolts etc and welded on would do the job nicely.....but...
check if it will need to be certed first. and the use of a hoist will definitely be of an advantage

Not needed for Cert as it is classed as a running repair.. A mate did exactly this and no cert needed.. Well that was a while ago now.. I have the same plate to go on my truck when I get roundtoit.. I can either take a pic or some measurements if you like.. It goes on the outside of the chassis, seemed to have worked out well as it hasn't cracked again since..

Big wrote:

mudlva wrote:it will be hard to get a plate in there as the crush tubes will stop anything from being push through the chassis section.

that said some nicely scribed 4mm plate drillout to suit the steering bolts etc and welded on would do the job nicely.....but...
check if it will need to be certed first. and the use of a hoist will definitely be of an advantage

Not needed for Cert as it is classed as a running repair.. A mate did exactly this and no cert needed.. Well that was a while ago now.. I have the same plate to go on my truck when I get roundtoit.. I can either take a pic or some measurements if you like.. It goes on the outside of the chassis, seemed to have worked out well as it hasn't cracked again since..

managed to get the service repair bulletin from toyota. the say to grind out crack in a v shape and to drill a 3mm hole at each end of crack. also to fully weld around the crush tubes as from factory they are only half welded.

"v" it and weld it

catalystracing wrote:

wopass wrote:Pull the box off and blaze it up bro.

Teenagers have a different meaning for blazing it up these days

wish i was a teenager sometimes

From and real engineering view, cracks most likely fatigue - ergo excessive stress in this area.
Ideal soln - Completely weld up every crack, and then consider strengthening for real long protection.
when welding up cracks:
First completely power wire buff area - then use red dye and developer to actually find all the cracks(you'll be amazed sometimes what you see)always grind out about 5mm beyond the tip of crack into clean parent metal if pos. Find a good welder- root profile is important - tig pref unless your a hotshot coded pipe welder, grind cap flat on outside surface. Crack test again so you know your welder mate actually done a good job. Dont leave undercut.

There is an approved repair method for this, having trouble finding the copy I have access to (my work produced the repair procedure many years ago). Speak to Howat Engineering, they have done a few including my truck. They may be able to send you the reinforcement plates for you to fit.

Howatt put one of there kits in and signed it off on my 80 also.
Very reasonable price also