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Sub-Frame Repair on a 2010 Ford Flex

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  • Ltbadd
    replied
    Originally posted by ryanjones2150 View Post
    You always do such a good job of taking pictures. I definitely suck at it.
    Grasshopper, you must see as the camera does...

    Leave a comment:


  • ryanjones2150
    replied
    You always do such a good job of taking pictures. I definitely suck at it.

    Leave a comment:


  • Don52
    replied
    Originally posted by MasterKwan View Post
    Looks good. What process did you use? It looks clean. Like maybe pulse-mig.

    I built some cups like that out of DOM tubing and then welded a plate on the end to cap the cup. Seeing what you did does make me want to find a lathe.
    I welded the cup to the plate using short circuit MIG using .035" wire on the SP-250 welder.
    I just welded it continuously tracing small "U" shapes.

    For welding the plate to the sub-frame I short circuit MIG welded it using the LE31MP welder, because I keep .025" wire in it.
    I manually pulsed by pushing the trigger and waiting until the puddle cooled off slightly and then advancing slightly and repeating the process.

    -Don

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  • MasterKwan
    replied
    Looks good. What process did you use? It looks clean. Like maybe pulse-mig.

    I built some cups like that out of DOM tubing and then welded a plate on the end to cap the cup. Seeing what you did does make me want to find a lathe.

    Leave a comment:


  • Don52
    replied
    We re-assembled the cup/plate assembly to the sub-frame. Then we welded the assembly to the sub-frame. The last step was to weld up the radial saw cuts.

    5. Plate welded in place

    Don

    Click image for larger version  Name:	image_36564.jpg Views:	1 Size:	64.7 KB ID:	591933

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  • Don52
    replied
    We made radial cuts in the plate and formed it to the shock tower. Next we bolted the steel cup to the sub frame. We held the plate in place and tack welded it to the steel cup. Finally we removed the plate/cup assembly and welded it out on both sides in a vise. Click image for larger version

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    4. Welding steel cap to plate

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  • Don52
    replied
    We manufactured a steel cup in the lathe. Notice the 1-1/2" drill bit. A 7-1/2 HP lathe has little respect for steel.

    3. Making steel cap
    Click image for larger version

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  • Don52
    replied
    In the following picture you can see a schematic of our approach. We manufactured a steel cup, which will serve as the new attachment point for the rack on the sub-frame. The steel cup is bolted to the sub-frame. The steel cup is fillet welded on both sides to a plate, which is in turn welded to the sub-Frame.

    2. Schematic.
    Click image for larger version

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  • Don52
    started a topic Sub-Frame Repair on a 2010 Ford Flex

    Sub-Frame Repair on a 2010 Ford Flex

    This week's project was to repair the attachment point for the steering rack on the sub-frame of my friend's 2010 Ford Flex, which he plans on keeping a few more years. I was surprised that it rusted completely though in eight years. My friend does lives one mile out on a dirt road, so dirt and calcium chloride that they put on the road to keep down dust, probably contributed to it. The following picture shows the rusted through steering rack attachment point on the sub-frame.

    1. Rusted rack attachment point
    Click image for larger version

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