Cracked sheet metal above radiator body bushings

Okay, update.

So I pulled the front end apart last night to get a better looks around. As I suspected, the only pieces that are cracked are the pieces I previously mentioned, the cleverly named "side panel". PN 53029-04010 and PN 53028-04010.

There are 8 spot welds holding each panel on. My plan is to drill out the center of the spot weld so I can pull out the cracked pieces. I will then be able to place in the new side panels with 1/4-20 SS hardware or something of the sorts. The only modification I will be making to the side panels will be to add a thin strip (1/4"-1/2") of 16 ga sheet metal to the edges of the panels to hopefully prevent tearing on the edges which leads to much larger cracks.

My thought behind doing this is nothing will be overly reinforced which should hopefully prevent the next weakest link from "going out" thus minimize gremlins.

Thoughts? Good Idea or am I hopelessly optimistic?

 

Could you please point out where to check for these cracks? Forward of the front shocks on the inside of the wheel well?

 

Its pointless. Only way to stop the cracking below the headlights is to plate the whole area like I previously showed. Adding a strip will either just concentrate the fatigue to the center of the area below the headlight or just crack through the strip.

Realistically the cracks won't affect most people and those that do have cracks, won't grow very fast. Mine appeared to grow about 3/4" over 400+ miles of dirt abuse. Most people won't do 100miles of dirt in a year.

 

well shit

 

Or just convert it into 1/4" aluminum that you guys have at the shop...

 

thats a ton of work and unfortunately a lot of shit ties into these pieces so keeping factory holes is desireable

 

I do....

 

Time to make an pure UpTop Overland built Tacoma?

 

send those parts to me..ill laser scan them and draw up a sturdier piece in Solidworks. Send ya the file to have laser cut and we can collab on it

 

Why not just drill out the old pieces, and spot weld or TIG in the replacements? If it's going to crack, it's going to crack. At least the third time you have to replace it, will be a quicker job.

 

It has a bunch of complex bends since it's stamped, but maybe if we have overall shape it could be doable

 

there is that too lol

 

Yes its a complex stamped part, but doesn't mean that it can't be redesigned using heavier gauge mtl and standard press brake tooling...might end up being multiple pieces formed then welded together...but something maybe worth the effort to solve the problem here.
if someone wants to pay for parts shipped to me I will undertake the engineering design challenge

 

instagram portfolio @jetg_design

 

Hm. Now I need to go home and look. I’ve heard some interesting loud pops while getting a little too squirrely in the ol’ dirty taco.

 

Where are you located?

 

well okay then, thats pretty slick!

 

Not bad.

 

Long beach California

 

Clearly you didn't beat on it hard enough. Hahaha.

I need more pics Wishbone! I had no idea you ended up doing this to yours as well!

No it doesn't help the cause. It just helps tie in the bumper assembly to the boxed portion of the frame rails. Good for towing from the front and winching.

You can, but then you can't remove your bumper unless you use tubing disconnects like the ones which Camburg makes.

I did the same with mine. It's been 5 or 6 years, and has handled all my wheeling shenanigans including the one which is on my sig picture like a champ.

That's disgusting. What GARBAGE.

It's more for collision stuff more than anything else. MPG and thesw trucks is a laughable thing to think about.

Just tighten them til they are good and tight. Torque spec is not important with these bushings. Agree though, these are self greasing because of the material they are made of. Unless you get those stupid red ones. Those are not self greasing.

DUDE! This would be the end all solution for sure! But you need to make the fender aprons for them as well if you are going to redesign the front otherwise this will be all for nothing.