Recently a customer (potential customer
at the time of contact) sent me an email asking a question about
trailer cracked frame repair. In his email, he didn't elaborate on
the exact location of the crack in the frame but just said it was in
the lower flange and web area.
I answered his email with the email
that follows:
“Trailer & tractor frame repair
is very different especially where cracked rails are concerned.
Tractor cracked rail repair is relatively simple (lots of work, but
simple) partially because the rails are made from channel type semi
hardened metal and each rail is more or less perfectly straight. This
repair is accomplished by supporting the frame evenly & straight,
welding the crack back up, then drilling and bolting in a piece of
frame rail or bought repair kit to the inside of both rails at the
same proximity.
On the other hand, trailer rails are made from
I-beam type metal and are arched so that the middle of the trailer is
higher than each end (for heavy load carrying on long rails). The use
of aluminum compounds the problem in most cases too. Some heavy duty
equipment must be utilized but, depending on the exact location of
the crack and severity of any lost arch, may be optional as to
exactly what that equipment could or should be.
Both steel and
aluminum frame rails can be welded but the arch must be restored
evenly before welding and maintained during welding. The arch can be
restored in steel trailers by simply cold bending to a certain degree
(if the arch is minimally reduced). If the arch is greatly reduced in
a steel trailer, an upside down V must sometimes be cut out of both
rails at the center of the normal arch then the arch restored and the
upside down V welded back up (upside down V should be closed up by
restoration of the arch at this point). Penetration of the welds must
completely through the metal so V the weld points with a grinder or
cutting torch (plasma torch works best on aluminum).
The
repair is similar with aluminum trailers, but the aluminum that is to
be bent must be heated to a certain temp range and then the arch
restored immediately while the aluminum is at that certain temp.
To
add strength at any welds, simply grind the repair welds flat then
weld a diamond shaped piece of metal over the repair welds. When
adding these diamond shaped pieces of metal, any added to one rail
must also be added to the opposite rail in the same proximity to make
the strength of the two rails the same.
A good wheel alignment
should top off any frame repair.
I certainly hope this short
version of an explanation helps you either in your attempt to do the
repair or helps in choosing who to use to help you with the repair
and/or equipment choices.”
Well, after he read this email, he
called on the phone and the conversation was more specific as to
location of the crack. Turns out the crack was in the area of the
suspension so there was no issue with lost arch.
To make things short, we discussed his
options for repair where I suggested welding up the crack, like I
talked about in my email, then welding a diamond shaped plate over
this welded up crack, etc. He asked if the book “Tire trouble?
Handling problems?” would help him do the repair himself, and my
response was, yes it would certainly be good reference material for
this frame repair plus the other money saving info the book provides
for both truck and trailer maintenance & repair. He ordered the
book off this website!
If he follows the advice contained in
the book, he will save hundreds short term and thousands long termed.
The book will enable him to correctly make repairs & maintenance
to the “dirty side” of his rig himself and/or limit commercial
shop involvement. Enlightenment alone tends to save money on any
large or small vehicle.
