Spring Hanger Repair

So on my recent trip out West, I managed to tear a spring hanger from my frame. The factory rivets and welds held, but the frame itself bent and cracked around the perimeter of the hanger, allowing it to come off.



Since we were so far from home and not near any major town, we had to ask around a few locals and we found the only guy in the area who can weld. He welded it up, but it's just a temporary fix that got us home.

Looks okay from here:


But from this side you can see that the bottom of the frame rail is still all bent out of shape:


I may be wrong, but as far as I know it is bad practice to weld perpendicular to the frame rail.


In this picture you can see part of the frame rail still has an exposed crack to the right of the weld.


These two pictures were taken from just above the bottom rail ("inside" the frame):



My question is, what needs to be done to repair this properly? I was thinking maybe cut off the hanger and the damaged section of the lower rail, then weld in a new section of lower rail with diagonally cut ends to avoid a seam that is perpendicular to the frame. Then reattach the hanger to that?

I don't have the welding skill or welder to do this repair, but I would like to do all the work besides the actual welding, ie the cutting and fit up of the repair piece.

Thanks

 

Not bad for a field repair, IMO. Got you home! I don't think the exact alignment of the hanger matters so much, except that its parallel to the frame. A little up/down at the front or back shouldn't matter.

I would consider leaving the repair in place, and adding a little reinfocement. The weld along the length of the frame looks pretty good, but the welds across the frame look a bit blobby. You can add a piece of steel across the open part of the channel, to the top rail. This will transfer some of the twisting force on the springs to the top rail. You can also lay strap steel in the channel on top of the bottom rail, and weld along the length.

 

Probably not kosher, but Me, I'd add a welded plate(s), with tapered ends to distribute the stresses.

 

You'll probably need to clean up each hanger and the surrounding area with a wire brush, sand blast or whatever you use to make an inspection.................a brace like tim mentioned above is a good Idea.........I started to use a piece 2x3 or 2x4 rectangular tubing that I cut the back off and then put a weep hole in and weld/ tack it in place.......others put a plate between the top and bottom rail...........just there to keep that area from flexing.

 

I like the way that is done. gives access to the frame. nice.

 

Boy does that look familiar!
http://earlycj5.com/xf_cj5/index.php?threads/todays-carnage.125690/

 

This makes me want to go out and check mine.

 

Here's how I reinforced the last set I worked on. Just a plate to help transfer forces to the top rail, fishmouthed to help allow some frame twist without cracking. Stitch welded, so if one weld cracks, it doesn't take the whole thing out.

 

Way to go.

 

That looks really nice, ITLKSEZ. I think I will go with something similar after replacing the damaged section of the bottom of the rail. I may go ahead and add the same reinforcement to all the hangers. I really do not want to have to deal with a broken hanger again.

Second question, what gauge metal did you use for the plate and what gauge is the frame?

 

Here's what mine looks like now.
Chuck cut a piece out of an old Jeep frame, with the hangar on it, that's about 8" long and goes maybe halfway up the channel. We cut a corresponding section out of my frame and welded it in.place and put this reinforcement over the top of it. The back side was boxed with another piece of that old frame.

 

The frame is generally 1/8" thick. I've found some areas to be closer to 3/16", and some a little thinner than 1/8", depending on the forming precess of the rails.

I used 1/8" plate for the reinforcements. If you make one point in your frame substantially stronger than the surrounding areas, you'll just be asking for cracks where the reinforcement ends.

 

I have my replacement section. I need to get that welded in, then I will make some reinforcing plates. Stay tuned.

 

Cut to fit:


Welded up: