Frame Cracks Question

babell2 · 10-08-2009, 01:14 PM

This is on a 1997 Club Car DS gas cart. I was asked to troubleshoot a headlight fuse blowing problem for a friend. What I found was a tail light wire being chewed by a crack at the rear edge of the cart frame. this section has the rear shackle mount for the suspension attached to the bottom of it and the rear seat foot rest attached to the rear of the area. You can see the back of the frame at the back of the rear wheel opening between the inner wheel well and the body. The repair will require removing the body, cleaning and compressing the crack in position and re welding the area. My reason for posting is to ask if any one else has found this type of failure? Also my 1999 frame is a constant square I beam to the end while their's has an angle so the web isn't supported by the top section at the end of the frame. Was this a design change to reinforce the frame?

scottyb · 10-08-2009, 01:38 PM

These frames are prone to cracks from rough use or constant rough terrain... Look up front too where the floor meets the sloping dash....

roady89 · 10-08-2009, 02:40 PM

You'll likely find more cracks the closer you look at it. Mostly small cracks around welds. The area scotty is talking about seems to be the most common area for cracks.

Aaron Hipps · 10-08-2009, 02:54 PM

Quote:

Originally Posted by scottyb

These frames are prone to cracks from rough use or constant rough terrain... Look up front too where the floor meets the sloping dash....

Yep thats where my frame is broke too. I'm gusseting and welding it up good. I've also noticed that a lot of the welds have little hairline cracks in them. I have my whole frame stripped down and am going over it and fixing weak spots. Aluminum is a real pain to weld. Still trying to get better at it.

babell2 · 10-08-2009, 05:45 PM

Quote:

Originally Posted by Aaron Hipps

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Yep thats where my frame is broke too. I'm gusseting and welding it up good. I've also noticed that a lot of the welds have little hairline cracks in them. I have my whole frame stripped down and am going over it and fixing weak spots. Aluminum is a real pain to weld. Still trying to get better at it.

Welding Aluminum can be done with a wire feed welder but a spool gun or a TIG is best.

DOOmsman · 10-08-2009, 06:08 PM

Quote:

Originally Posted by babell2

Welding Aluminum can be done with a wire feed welder but a spool gun or a TIG is best.

AND ARGON GAS

crash12888 · 10-08-2009, 07:54 PM

I got gas!

Aaron Hipps · 10-08-2009, 08:12 PM

Quote:

Originally Posted by DOOmsman

AND ARGON GAS

I'm using a Ready Welder(which is basically a spool gun) and running off four golf cart batteries (24 volts). 100% argon of course. It works OK when it works but I'm having wire feed problems and wire burn back into the tip.

babell2 · 10-08-2009, 09:12 PM

If the wire is burning back into the tip increase the feed rate. That should keep the wire in front of the tip when it melts. my wire feed welder will do light repairs but tends to bird cage the aluminum wire at high feed rates.

scottyb · 10-08-2009, 09:45 PM

HUh

I just take my aluminim repairs to a master welder....

.... put on a helmet and watch those pro TIG repairs

10-08-2009, 01:14 PM	#1
babell2 Not Yet Wild Join Date: Aug 2008 Posts: 16	Frame Cracks Question This is on a 1997 Club Car DS gas cart. I was asked to troubleshoot a headlight fuse blowing problem for a friend. What I found was a tail light wire being chewed by a crack at the rear edge of the cart frame. this section has the rear shackle mount for the suspension attached to the bottom of it and the rear seat foot rest attached to the rear of the area. You can see the back of the frame at the back of the rear wheel opening between the inner wheel well and the body. The repair will require removing the body, cleaning and compressing the crack in position and re welding the area. My reason for posting is to ask if any one else has found this type of failure? Also my 1999 frame is a constant square I beam to the end while their's has an angle so the web isn't supported by the top section at the end of the frame. Was this a design change to reinforce the frame?
babell2 Not Yet Wild Join Date: Aug 2008 Posts: 16

10-08-2009, 01:38 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,408	Re: Frame Cracks Question These frames are prone to cracks from rough use or constant rough terrain... Look up front too where the floor meets the sloping dash....

10-08-2009, 02:40 PM	#3
roady89 nimda Join Date: Jun 2007 Posts: 13,022	Re: Frame Cracks Question You'll likely find more cracks the closer you look at it. Mostly small cracks around welds. The area scotty is talking about seems to be the most common area for cracks.
roady89 nimda Join Date: Jun 2007 Posts: 13,022

10-08-2009, 07:54 PM	#7
crash12888 Gone Crazy Join Date: Jan 2007 Location: Chesterfield, Va Posts: 6,021	Re: Frame Cracks Question I got gas!

10-08-2009, 09:12 PM	#9
babell2 Not Yet Wild Join Date: Aug 2008 Posts: 16	Re: Frame Cracks Question If the wire is burning back into the tip increase the feed rate. That should keep the wire in front of the tip when it melts. my wire feed welder will do light repairs but tends to bird cage the aluminum wire at high feed rates.
babell2 Not Yet Wild Join Date: Aug 2008 Posts: 16

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10-08-2009, 09:45 PM	#10
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,408	Re: Frame Cracks Question HUh I just take my aluminim repairs to a master welder.... .... put on a helmet and watch those pro TIG repairs

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