frame welding

[malibu79]

so i ordered my rear frame rails for my malibu what do u think is the best way to weld the to together--butt weld --Z weld--or plates over a butt weld .what do tou think give me some ideas??

[abadsvt]

I am not sure what your setup looks like but when i weld up my frame this is what i did. I did a butt weld but i grinded one side of each piece to an angle that way when you put the two pieces together it forms a "V". That is so when you weld it up you weld both sides of the steel. Also when you grind down your weld you have some weld left in the joint. Then i would recommend putting a gusset over the welded area. I know some don't but i feel more confortable knowing there is extra strength in the welded areas. Here is a pic of my gusset and underneath it is welded just like i explained. Good luck and feel free to ask any more questions if you have any.

[MtotheIKEo]

butt weld then weld a fish plate over the joint. Bevel one side of the butt weld so you get good penetration.

[MSM69Z28]

do you guys recommend a 2"x4"x.120 (1/8") for your frame rails?

[V8TV]

Originally Posted by abadsvt

I am not sure what your setup looks like but when i weld up my frame this is what i did. I did a butt weld but i grinded one side of each piece to an angle that way when you put the two pieces together it forms a "V". That is so when you weld it up you weld both sides of the steel. Also when you grind down your weld you have some weld left in the joint. Then i would recommend putting a gusset over the welded area. I know some don't but i feel more confortable knowing there is extra strength in the welded areas. Here is a pic of my gusset and underneath it is welded just like i explained. Good luck and feel free to ask any more questions if you have any.

This looks nice... you could also add some plug welds in the gusset body to take the load off the edges.

[abadsvt]

Originally Posted by V8TV

This looks nice... you could also add some plug welds in the gusset body to take the load off the edges.

Thanks for the complements! I thought about that but since it is fully welded below the gusset i figured that this is overkill already. I have seen tons of show cars and trucks that don't even gusset the original butt weld. I wanted just a little more reasurance. Good idea though!

Josh

ps. MSM69Z28 .120 wall 2x4 tubing will work great. That is what i used on mine. Just remember when you make your brakets and so on that it is only .120 wall so you might need to reinforce the tube steel when there will be a fair amount of force. The .120 tubing when pushed in the center on the tall side will have some deflection. I hope that mades sence.

Josh

[MSM69Z28]

thanks. actually bought 3/6 wall (.188). figured for the length i need, its a 20lb difference overall.