'74 Charger SE Front Frame Rail, Fixable, or Replace?

[mrlizard]

I'm working on a 1974 Charger and the front driver side frame rail is rusted through in a few spots in one section. I was wondering if it would better to replace it or if patching it would work and be safe. I would just replace it but finding a frame rail has been quite difficult. So before I sink a bunch of time into trying to find the part, I wanted to see if a patch would be possible in the hands of an expert. The rest of the frame components seem ok, although the floor pan is pretty much destroyed, but thats replaceable.

So to bottom line this, can this be repaired, or does it need to be replaced, and with this damage is it worth continuing or is this project dead in the water?

 

[70chall440]

I am sure you are going to get differing opinions on this but... yes it can be repaired BUT are you willing to spend the time, energy and money to do so?

You need to cut out the rot and replace it with good metal, do one spot/section at a time until you get them all done.

It is not real thick metal, I think around 14 or 12 gauge sheet metal. You would want to support the repair spot on both sides so that it isn't a hinge point meaning it would move once you cut out the bad metal.

This is a great time to put in some sub frame connectors and torque boxes first, this will help support the car once you start cutting.

 

[Dodge33]

I am sure you are going to get differing opinions on this but... yes it can be repaired BUT are you willing to spend the time, energy and money to do so?

You need to cut out the rot and replace it with good metal, do one spot/section at a time until you get them all done.

It is not real thick metal, I think around 14 or 12 gauge sheet metal. You would want to support the repair spot on both sides so that it isn't a hinge point meaning it would move once you cut out the bad metal.

This is a great time to put in some sub frame connectors and torque boxes first, this will help support the car once you start cutting.

I do appreciate what 70chall440 has told you,
as he is very correct on the proper way to go about fixing your front frame rail! Another option here........ we have a pair of 73 Charger front frame rails that have been all drilled off properly, and have been hanging in our frame rack for 20 years. They are from way out west
and are in clean condition. We will take a very good look at them, as soon as we get the chance if interested.

 

[70chall440]

I do appreciate what 70chall440 has told you,
as he is very correct on the proper way to go about fixing your front frame rail! Another option here........ we have a pair of 73 Charger front frame rails that have been all drilled off properly, and have been hanging in our frame rack for 20 years. They are from way out west
and are in clean condition. We will take a very good look at them, as soon as we get the chance if interested.

This is definitely a great option.

 

[#41]

First poke around and see how extensive the rust is. It's always more widespread underneath than is visible. That will tell you if you can get a way with patching things with sheetmetal or should find some replacement rails.

 

[WileE]

And remember my proverb : "Where there's rust... there's more."

 

[Takoctopus]

I would be surprised if the k frame mounting area is solid still seeing the rust right behind it. Be real gentle if you decide to remove that k frame bolt right near the rust. Might just completely rip out. Also under those rubber mounts rust is usually hiding on the K frame itself. Your K frame might need repaired also. My 74 roadrunner required frame rails and k frame.

 

[mrlizard]

I do appreciate what 70chall440 has told you,
as he is very correct on the proper way to go about fixing your front frame rail! Another option here........ we have a pair of 73 Charger front frame rails that have been all drilled off properly, and have been hanging in our frame rack for 20 years. They are from way out west
and are in clean condition. We will take a very good look at them, as soon as we get the chance if interested.

Nice, this would honestly be my preferred option is just replacing the rail. When you do get a chance to take a look I'd be interested in them.

 

[mrlizard]

I would be surprised if the k frame mounting area is solid still seeing the rust right behind it. Be real gentle if you decide to remove that k frame bolt right near the rust. Might just completely rip out. Also under those rubber mounts rust is usually hiding on the K frame itself. Your K frame might need repaired also. My 74 roadrunner required frame rails and k frame.

Yeah i wouldn't be surprised if that's the case, i haven't been able to really get under the car yet. Might just wait until I take the engine and trans out before trying to get at the k frame, I need to buy the stuff to do that but I've been hesitant until I have a good plan in place to address the frame rail rust.

 

[mrlizard]

I am sure you are going to get differing opinions on this but... yes it can be repaired BUT are you willing to spend the time, energy and money to do so?

You need to cut out the rot and replace it with good metal, do one spot/section at a time until you get them all done.

It is not real thick metal, I think around 14 or 12 gauge sheet metal. You would want to support the repair spot on both sides so that it isn't a hinge point meaning it would move once you cut out the bad metal.

This is a great time to put in some sub frame connectors and torque boxes first, this will help support the car once you start cutting.

Cool, this confirms that even if I'm unable to get a replacement rail, it can at least be repaired. I've got plenty of time and energy, which helps make up for the lack of money lol

 

[70chall440]

Let me add this, it is not super hard or complicated. Take a lot of pictures and more importantly a lot of measurements if you are going to do say an entire frame rail. If you are just needing patches then cut out that part and replace it. That said, when you do cut open a section take the time to spray in some rust converter or something else to help to protect the remainder.

Also remember that the rust you see is probably a lot less than what is actually there. Make good patch panels and ensure you get good penetration on the welds. If done right you will make it stronger than new.

Good luck and have fun.

 

[matthon]

I had similar rust in the same exact area on my 62 Dart, except it extended all the way to the torsion bar cross member, included the cross member, floor, firewall, cowl, etc.

Back to the front frame rail, I cut out the section needed from a donor.
Drilled holes in the 'new' section and the existing rail, cut plates that fit on both sides of the new section and the bottom.

Plug welded the plates inside the new section, slid it into the car, plug welded in, then welded the seam.

Made a much stronger repair, easier too, and provided metal behind the cut seam in the rail that prevented any blow through.

Oh ya, and I never picked up a welder beforehand.

 

[eldubb440]

faster, easier, and better to grab both rails available.... and install them

one at a time with k frame in place as a locator