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Don52
Don52
Senior Member
Last Activity: 09-11-2018, 07:47 AM
Joined: 10-17-2008
Location: Troy MI
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  • Don52
    replied to Sub-Frame Repair on a 2010 Ford Flex
    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

    ...
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  • Don52
    replied to Sub-Frame Repair on a 2010 Ford Flex
    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...
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  • Don52
    replied to Sub-Frame Repair on a 2010 Ford Flex
    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

    ...
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  • Don52
    replied to Sub-Frame Repair on a 2010 Ford Flex
    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...
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  • Don52
    started a topic Sub-Frame Repair on a 2010 Ford Flex

    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...
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