Crossmember rotted out

[jjk1224]

Hey guys, my radiator support rotted out where the crossmember attaches. Now my engine is basically supported by my sway bar. Has anyone had this problem? I'm thinking about welding some flat stock to the radiator support that is clean and welding the crossmember straight to that.

[Damkid]

That is a very common spot for these cars to rot out so welding in a new piece of steel is about the best solution

[BigElCat]

I wouldn't weld the cross member to the flat stock, though. Slip the flat in, weld it, then drill a hole to bolt the cross member.

[Basement_Modder]

Cut the rad support out at the rotted area, then take some appropriate gauge sheetmetal and shape a patch to go across, or use square stock and cut reliefs and bend as needed. Weld it extremely well.

[gauge_half_inch]

I've had it break completely on my first, then it almost broke on my second. Both times I uses 2" box tubing and some 1/8" plate to reconstruct it. The last time I did it o measured out all the bolt locations and made tab nuts, drilled the appropriate size holes and smaller holes on each side to weld the tab in place, made it a lot easier to reassembled. The first time I drilled all the way through and used longs bolts.

[Movin]

There are rubber washers in the crossmember bolts, they isolate engine and transmission
noises like the rubber engine and transmission mounts do. Solids work but they function
harshly and are noisier than heck. This includes the rubber and sleeve set up for the cross-member bolts. Or get a big radio!!

[CharlieZ]

I was able to slip a flat piece inside the rad support. The flat piece has aircraft 'plate nuts" attached in the correct location for the tranny cradle. Got new rubber bushings from dealer (old stock). Used hi grade bolts with steel bushings to simulate the shouldered OEM bolts. The flat piece is bolted in to the strong areas of the rusted rad support. The bolts pick up newly drilled holes and more plate nuts on the flat piece. Has been working well fo several years. Another member used longer bolts that go completely thru the rad support thur an angle iron along the bottom, bridging the rusted section then into the tranny support. Can't find it but it's here somewhere on the forum.

[jjk1224]

Just in case anyone is interested in the repair I made, here are some pictures.




Cut most of the rot out with a plasma cutter and die grinder.




Bent up and welded in some 16 gauge sheet.



Welded some nuts to a plate for extra support.



Sprayed it inside with bed liner, welded a plate to the front and finished it off with some more liner!



Good as new!

[gauge_half_inch]

Very clean repair.

[denguy]

Looks like there is a lot gone from that crossmember.

[jjk1224]

What do you mean? Its rusty but solid.