Rear Frame Repair 66 Fairlane

Rear Frame Repair (This is on a 66 Fairlane)

by: Jerry Pounds

If the frame rail is rusted beyond repair and the rust took its toll
beyond the leave spring mounting area then this technique may be helpful.

1. Measure the rail length, width and x measurement of rear frame/unibody.

2. Remove the floor panel that is welded over the frame rail. disconnect the leave spring.

3. Measure and cut the old rail past rust damage and note the measurements used.

4. Cut the used or nos replacement rail leaving tab with hole as shown in the picture. check the fit with the tab with
the hole lined up. clamp in place where you think it looks correct. measure the rear unibody remove and trim parts
if nesessary and refit and measure.

5. Once measurements are correct cut the tab off, prep and refit and remeasure.

6. If the rear body panel is fitted and clamped to the rear portion of the frame rail. welding can now be done.
tack weld and remeasure. weld the two flanges and the bottom leaving the sides un welded. grind
down the welds on the flanges.

7.build a sleeve from old piece of left over frame rail, use a solid piece as shown in the picture.make this piece fit
to where there is about a half inch clearence on bottom so condinsation can drain under the sleeve not trapping
water to cause rott out. drill holes as shown in picture.

8. Weld the sleeve in on the inside of rail. make sure your welds have penitration.

9. Weld the butt joint sides of the frame rail allowing weld penitration to the sleeve.

10. Grind down the exterior welding job on the exterior portion of the section leaving weld a little tall for strength.

11. Spray inside of frame rail before welding top floor in to seal the welding ares from rusting using
corrision fighting primer and single stage enamel.

12. If doing show car you may use plastic filler and hide the butt joint site. but first weld the rear body panel
top floor section in.

14. Grind all welds to look good leaving a little tall for strength. do plasic filler work, primer and paint.

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