SHE'S Ripping apart!!!!!!! (Click bait, I knew it was coming)

As the thread states mine is finally succumbing to the known issue of the core support area ripping apart and on the PS completely through. Not like this is anything new as this is known especially if you wheel the thing. I would like to eventually do something like that other 2nd gen with some welded square tube (guy with the DCLB out of CA LT and the works forget his TW handle). In the mean time I'm just going cheap and self tapping screws and some stud ties to hold it together. When I noticed mine starting to crack is when I started getting the notorious hood flutter going down the highway (@boogie3478 this could be your culprit). My quest is to actually stiffen up the front section of frame to help alleviate the amount the frame twists as that is IMO why this happens. Too much twisting of the frame transferred to the body that is significantly weaker.

My plan cont. onto next post. @Dalandser and @In4aride this is what I was hinting at the other day and would like some other ideas kicking around as to help alleviate the issues.

Here is the tears: I'm pretty sure there is more I just can't see that easily. Ignore the zipties they hold the wires for my rock lights.
DS under headlight

PS under headlight

PS upper core support, she's in 2 pieces bitches

PS where headlight access hole is

DS upper core support

DS headlight access hole

More DS headlight access hole

 

The plan. I've been planning on cutting that dropped down crossmember at the very front and moving it up to the frame then adding some gussets as space allows to get some triangulation into the frame there similar to @EatSleepTacos . Also plate the outside and some on the inside of the front frame horns to add some rigidity. I'd like to if room allows to add some gusseting to the frame around the drops for the front suspension crossmembers (this might not really add any rigidity) just a thought. I've been looking at Solo Motorsports strut relocation deal and then doing a good bolt on engine cage but with like a solid either aluminum or bronze bushing vs the urethane most do. Again this is to try and stiffen up the frame as much as possible.

 

Mine

 

last mine just in case I need it

 

@Sterling_vH111 and @snowsk8air2 have nice engine compartment setups.

Here's @Sterling_vH111






@snowsk8air2

 

@SearArtist posted up a tear in his! I was scared to go look! But I finally did! I'm still solid!!

 

The 2 lower ones have been tearing for a while now the upper ones and behind the headlights are fairly new but wheeling a lot I figured after seeing a few it was bound to happen. I'm not upset.

 

I like those also lots more room for activities with big tires.

 

Oh shit. Dude that sucks? Ive actually never seen that. What causes that to happen?

 

Heavy battery / radiator and paper thin sheet metal mixing.

 

The frame twisting up a lot and wheeling it pretty hard also Jumping it doesn't help either. Next time you go wheeling watch the front end of the trucks with aftermarket bumpers when they get flexed out you'll see one side with a big gap on the bumper and the other side where that gap disappears the frame twisted enough and transfered that force into the body which the front mounts are located right at the core support on these trucks.

 

What's funny is my PS is worse than the DS, oh this is also the reason why my batt. is getting switched to a small AGM and put under the bed on the PS in it's own little cubby.

 

Twisting like this? This was from this weekend.

 

Maybe frame flex has been doing more for your damage - in trucks that get jumped the battery usually is the thing to get the most cracks around it.

 

Why didnt i buy a jee...

 

I have no doubt on that! I've only gotten air born any significant amount a few times even those it's nothing like ya'll do on the west coast. We don't really have the room or the trail systems to air them out like that.

I notice it more when coming down trails and obstacles but yes like that. I've got my rear frame boxed and an added crossmember in there to help some.

 

#fiat #reliability

 

I’ve been planning a fix for this for some time. Planned on making a whole new core support structure out of square or round tubing that would bolt in to stock location and have mounting tabs for everything else to bolt back in place. I haven’t gotten around to it because it’s really not a priority but something I’ve been noodling with. Seems doable and if a build a jig in the process I’d be able to replicate it as many times as I’d want. It could potentially (and extremely likely) bring up the next weak spot in the front end, but until someone builds it, we won’t know how far to chase the repair.


I’ve seen a few solutions out there, but they’ve all been one-off. So curious what you can come up with.

 

@desertjunkie760 should be in here, his is at least as bad if not worse and has been kicking around several ideas on how to fix it. My solution of a replacement front end and a replacement truck is not a great one for most people.

 

It's not a priority for me either and temp fixes will work to slow the issue down.
Mine would be one off as well. But I'm looking at trying to limit frame twist as well since that's really where I think mine comes from. It literally makes some awful noises when I get all twisted up you can hear the sheet metal just screaching as it tears more.

I'll probably take a bunch of the different things that has been shown here and what I've seen on the pre-runners and kinda do a mix bag of it all trying to incorporate as much of what I see as some killer ideas into it.