Anybody welded on their 2nd Gen frame?

It seems I have developed a small crack in my frame where the a arm mounts to the frame. I'm a good welder and I'm thinking about running a bead down the crack and then putting a 1/8" plate across the thing and welding all 4 sides of the plate to reinforce it. Maybe a bad idea? Let me know what you all think.

 

I'd see what Toyota could do first. Most likely nothing but who knows maybe a frame recall for 2nd gens may happen.

 

If you're a competent welder, reinforce the entire frame if you want.

 

That's an odd place to get a crack! Try your idea out. You have nothing to lose! Make sure you paint the bead shortly after you weld it and the plate over it as well to ensure that you will get max paint adhesion to avoid rust in the surrounding area.

 

Already checked with Toyota and they wouldn't help so I think this is my project for the day

 

Frame recall is in full effect for rust. That frame doesn't look rusty at all though. On an '05, I'd say weld it and be done. I'm guessing you run it pretty hard somewhere dry and sandy, judging by the available info. If you're a competent welder, just keep patching everything that pops up (or off!).

 

Damn, something new to go look for, good luck with the fix

 

Yes I do run it hard. This is my first frame repair so I was just checking to see what you all thought. I've welded a lot of things to the frame but haven't actually attempted to repair it yet. Hopefully it works well

 

All the welders I know overbuild everything. I'm sure you'll do fine

 

Drill out ends of crack reweld.

I'd check with toyota first before touching though.

 

When I talked to Toyota they told me to bring my truck and they would look at it. Then they asked if I had done any modifications to the frame or if I knew of any reason it could be weakened. So I was like yeah I've done quite a bit to the frame and they basically said they probably wouldn't be able to help but I could bring it in for an inspection if I wanted. But I've got the weekend to work on it so I'm just gonna try it

 

You're overthinking. Drill the end and lay a bead and be done haha

 

I take it drilling he end of the crack stops the progress? Pretty cool tip that I personally hadn't heard of before.

 

Yes thats the idea. I haven't tried to drill it yet but I've heard the frames are very difficult to drill through for obvious reasons so I'll try but not sure if it will work

 

yes, the frames are a bitch to drill

 

Yes, it actually comes from the aviation world.

 

I found the Taco frame to be fairly soft. Just use a new sharp bit, oil, a lot of pressure, and run the drill slooooow. It will cut pretty quickly.

 

Drilling frame isn't bad. A cobalt bit in my little 12V cordless did fine for me. Low rpm and really push on it.

 

Impact drivers work grest if you have the bits with the hex shank. A unibit works too. I've popped holes in my frame in a couple seconds with my Ryobi One impact driver. MUCH easier than a drill

 

I used a 1/2" step bit when drilling mine. Used some WD40 and it drilled through the frame like butter.