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Sub-Frame Repair on a 2010 Ford Flex

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  • Sub-Frame Repair on a 2010 Ford Flex

    This week's project was to repair the attachment point for the steering rack on the sub-frame of my friend's 2010 Ford Flex, which he plans on keeping a few more years. I was surprised that it rusted completely though in eight years. My friend does lives one mile out on a dirt road, so dirt and calcium chloride that they put on the road to keep down dust, probably contributed to it. The following picture shows the rusted through steering rack attachment point on the sub-frame.

    1. Rusted rack attachment point

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Name:	1. Rusted rack attachment point.jpg
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    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    In the following picture you can see a schematic of our approach. We manufactured a steel cup, which will serve as the new attachment point for the rack on the sub-frame. The steel cup is bolted to the sub-frame. The steel cup is fillet welded on both sides to a plate, which is in turn welded to the sub-Frame.

    2. Schematic.

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Name:	2. Schematic.jpg
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ID:	701972
    sigpic
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      We manufactured a steel cup in the lathe. Notice the 1-1/2" drill bit. A 7-1/2 HP lathe has little respect for steel.

      3. Making steel cap

      Click image for larger version

Name:	3. Making steel cap.jpg
Views:	19
Size:	61.7 KB
ID:	701974
      sigpic
      Miller Thunderbolt
      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Lincoln LE 31 MP
      Clausing/Coldchester 15" Lathe
      16" DuAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport

      Comment


      • #4
        We made radial cuts in the plate and formed it to the shock tower. Next we bolted the steel cup to the sub frame. We held the plate in place and tack welded it to the steel cup. Finally we removed the plate/cup assembly and welded it out on both sides in a vise. Notice that it is still red hot in this picture.

        4. Welding steel cap to plate

        Click image for larger version

Name:	4. Welding steel cap to plate.JPG
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ID:	701976
        sigpic
        Miller Thunderbolt
        Smith Oxyacetylene Torch
        Miller Dynasty 200DX
        Lincoln SP-250 MIG Welder
        Lincoln LE 31 MP
        Clausing/Coldchester 15" Lathe
        16" DuAll Saw
        15" Drill Press
        7" x 9" Swivel Head Horizontal Band Saw
        20 Ton Arbor Press
        Bridgeport

        Comment


        • #5
          We re-assembled the cup/plate assembly to the sub-frame. Then we welded the assembly to the sub-frame. The last step was to weld up the radial saw cuts.

          5. Plate welded in place

          Click image for larger version

Name:	5. Plate welded in place.jpg
Views:	19
Size:	64.7 KB
ID:	701978
          sigpic
          Miller Thunderbolt
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Clausing/Coldchester 15" Lathe
          16" DuAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment

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