Fixing a poorly welded frame....

When I replaced the front crossmember on Ozelle the '55 Ford (the one that's bad to rust out on '54-'56 Fords and Mercs), I discovered that the original crossmember was only welded on one side at the factory. The tab that extends through the hole in the frame rail and is bent over to locate the crossmember before it is welded in was all that was holding it on the passenger side. Driver's side was welded as it should be both where the crossmember meets the rail and where the small angle brace butts up against the crossmember. The passenger side didn't get welded at all, guess the guy at the Memphis assembly plant on July 21, 1955 who was supposed to weld that side had to go to the restroom or take a smoke break when that car went by his station. Inspector must have been similarly indisposed. Car made it 55 years and 205,000 miles that way. The replacement crossmember got welded in solid with the trusty old Lincoln buzz box.

 

Words to live by!

That can be corrected properly, but you're going to need to tear it down the suspesion and remove all that you can in that area. Look for any damage, buldges as previously posted. Got to be clean, if you want perfect welds. Welding over dirt grease, rust, paint, under coating all take their toll. Those welds look new but the dirt and grease look to be original equipment.

 

I have encounterd simialr conditions. Just grind everything flat and then fabricate a custom fit fish plate to go overtop of everything. Drill some holes in the fishplate that you can plug weld.

It's a lot of work but the car may survive.

Scott
Welders360

 

at least the OP started off by asking how and whether to fix it. this is why some new bloods get pissed off and fade away.