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Discussion Starter #1
So I was under my truck the other day adjusting the parking brake, and noticed that my frame has completely cracked in half, right behing the front leaf spring mount under the bed. Attached are pictures, the frame is not connected at all. This is on a 97 1500, the rest of the frame is in good shape, so I'd like to try and salvage this if I can. What would be the best way? Would plates on each side be good with bolts through them? Then completely weld those too? Or no bolts because they could weaken the frame?

Any ideas or help would be greatly appreciated, thanks
 

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You are going to have to disconnect the leaf spring and possibly remove or lift up the bed to access it. "V" out the crack then get it straight as possible then weld it. For added support after you weld it put plates over it and weld then on. I would inspect the other side in the same spot for cracks.
 

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Discussion Starter #3
Good advice, thanks. I'll be dropping the tank and taking off the bed this weekend it looks like. Try and fab up some plates and see what I can do, I'll post some more pics once its torn apart
 

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another option is to get a donor truck and just swap frames. Tedious but not a hard project plus you can prep the frame (paint/powder coat). if the truck is in great shape, may be worth the time.
 

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Go to a professional frame repair shop. They can decide whether the frame is salvageable or not. It would take a deep penetration arc welder to attach sister plates but I doubt that the frame is thick enough for an effective repair - or it would not have cracked.

Starting in 2011 with the GM/Chevy heavy duty trucks, and in 2013-2014 with the Ram trucks and in 2015 with the Ford super duty trucks the new frames were fully boxed and much stronger and able to support the stress of much heavier tow loads.
 

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Discussion Starter #6
Well, finished it up and got everything put back together last night. I ended up making a large "C" of 1/4 in plate around the original frame, then bolting it together and welding all seams. Attached are pictures of the progress and finished product. As you can see, there was a lot of rust in this area, behind the fuel tank. I think the best way would of been to find a rust free section to weld in as mentioned above, but this should hold for a while.
 

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glad you figured it out. hope it holds out for you. not to be a dick but typically you don't want your weld to go in line with the crack/seam you're trying to fix. you have a bunch of metal that's missing so I'm guessing you did the best you could. from the looks of things, your frame doesn't really have much time left in this world...

good luck to you!
 

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they look like decent overlays! did you apply any plate inside the C channel
 
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