Rebuilding The Rusted Out Chassis On Our Square Body - Carcass S2, E2

[@ratfink9205]

I'm amazed at the mental gymnastics they went through to calculate the bends in c-channel that could have been done in a few seconds with a piece of cardboard.

[@Happyfacehotwheels]

And I thought they were only for holding pizza 🤔

[@walker7155]

haha that’s smart. I’m a welder and honestly I was just lost through most of this.

[@thebrain7065]

Lol..I appreciate the effort it took to come up with all that, but...yes...could have been done in a lot fewer steps....old school way. But...what do I know....I'm from the South side of Chicago here on vacation.

[@Artoconnell]

@@thebrain7065 Fantastic vacation quote, well done.

[@LukeEdward]

Jeremy, Jimmy, you guys really have taken a great turn in your show. The biggest thing is that your deliveries to the camera, and personal interactions, do not seem forced. Really, it seems quite natural and appealing. Maybe you two are dialing it down from what your every day would be, but the way you two are presenting yourselves draws the viewer in to what to be a part of, or at least learn from, what you are doing. Whomever decided the direction of the builds should also be commended. Your builds are not so polarizing (to be tactful). I still am anticipating, really, looking forward to something “non-traditional” in the builds to come, but I’m not expecting you guys to happy-yell at me that you are taking an old Port-a-potty truck and making it into a hovercraft you call “THE FLOATER.”

[@wicked650s]

It's great to see Lloyd and Harry finally get seriuos.

[@Happyfacehotwheels]

🤣🤣🤣

[@metalmindedmaniax]

😂

[@op_s_lead]

Saturday mornings just like in the old days

[@brianrocco4301]

The direction of this show is awesome! Very educational and tons of fabrication knowledge here. Very natural and confident chemistry!

[@bradywilliams2666]

Basic squarebody knowledge. 1 ton perches are 40" center to center. 1/2 ton and 3/4 ton are 42".

[@skandia4x4]

No fishplates to the new new frame section 😬

[@andyleo8418]

I notice these type of videos attract a lot of YT experts in the comments. 😂

[@jameskahlerjr.]

good luck doing this truck man and keep going get it done .want to see more of your working on this truck .

[@wyattoneable]

Thanks guys. The math to find the bend line was great.

[@marksam6824]

Hi carcass guys great builded, we do not see truck like this in South Africa 🇿🇦. 👍

[@David_does_it_all]

Bet you dont

[@gregholloway2656]

Neat project! I had to do a similar repair on my 1977 C10, 20 years ago, and it's still holding up fine. For those who might need to do a repair like this (at least on a half-ton), there's an easier way. First, forget the made-up channel section. Just use 4x2 HSS (I used 3/16" wall, these guys used 1/8"). Weld some cross members, like angle, across the chassis at a number of points, to ensure the original rails stay parallel and spaced correctly. Then remove all the original crossmembers (at the front spring hanger, and back of chassis), and spring hangers. Now, use a grinder or plasma to cut out the *lower* flange of the original frame rail, where it humps up and over the axle. With that done, it will be possible to slide the 4x2 steel INSIDE the original frame rails, from the back, pushing them forward. The original frame will nearly hold them in the perfect location, no measuring. Start tacking them into the frame, but only at the front, where the overlap between the old and new occurs. Then tack in the 4x2 crossmembers, noting that the front member (front spring hangers) needs to be flat/horizontal to clear the driveshaft. Once everything is checked, weld it all, and at the front, gusset between the bottom flange of the original frame and the bottom corner of the 4x2, about 2" high, to box all this in. Next, carefully cut the old framerails so that they can be slid off over the new 4x2 steel. Then attach the spring hangers (I bolted) and axle bump stops, and shock mounts. That's pretty much it. If anyone wants to know more, just ask.

[@jc-meza]

What kind of steel do you use? Can you use A36 mild steel?

[@gregholloway2656]

@@jc-meza I just used mild steel in a rectangular form (known as HSS). Welds easily and is plenty strong enough.

[@jc-meza]

@@gregholloway2656 Thank you! 😎👍🏼

[@dodgeguyz]

Are there no more square body frames available anywhere in the country! Sheesh! And I love all the weld through primer they used in the welds!

[@TheJesterstoybox]

This is some serious work, great job guys! Looking like great progress 💪

[@fordinlinestraight]

Great job guys! Spot on

[@Happyfacehotwheels]

I remember when I was a kid I used to watch Stacy David's trucks! I didn't realize standards have fallen so much.

[@harveylong5878]

stacy wouldve either fixed that clapped out chassis or swapped over to something more modern. PN has to appease their corporate overlords these days. kinda surprised there wasnt a $10k custom built chassis slapped under that thing

[@Hyprmtr]

These guys must have started watching Pakistani truck here on YT.

[@Happyfacehotwheels]

The only difference is these guys have better tools. Still sketchy af and most likely to break in half.

[@fritzpagaduan9854]

Exactly... Haha

[@adityaniyogi330]

Lol

[@superdad2150]

They clearly demonstrated how NOT to replace rusted out rear channels

[@Hawkers02]

I would have just gotten a new frame

[@ronniebenoit7699]

Maybe a cut at a 45° angle to have more surface area to weld and add a backing plate...but, maybe that's why we're not on TV 🤷🏻‍♂️

[@ronniebenoit7699]

@@bigboreracing356 uhhh...... a 3G weld has nothing to do with structural strength

[@ronniebenoit7699]

@@bigboreracing356 not really trying to show off but,that is a blind weld were its welded behind the face of what your looking at....its more common on handrails and ornamental work....very seldom would you see that on a structural job. Unless the design was revised during erection.. I'm not really into a pissing contest. I just had earthquake wire and 1" certs....

[@Pendaws]

I wish I could have had you fellas with me in Maths at School in the 60s :)

[@russellhartwell5404]

,, ,, M Y, # 1 0, "FINGERS," !!, HELPED, !!, " M E, " !!, I N, , , , " M A T H, " !!,

[@toosunakabooma1213]

To my 10th grade math teacher Mr. Whyte who turned a fast track to fail and self pity to a career of endless possiblities and common ground with my most feared and hated enemy... Numbers....

[@calvincrews3885]

They did a awesome job with the new back half rear chassis suspension all that full frame need is some paint or Powdercoated with any color

[@Stackali]

actually they really didn't. kzbin.info/www/bejne/r6LLZIOYpNCkgqs this is how to add to an existing frame. fish plates. that straight weld is gonna break

[@lawrencefoster2120]

I operated a shear for a couple years in a mechanic shop in Houston. It was a good experience they had everything.

[@Lashazior]

This is what Carcass should have been last season. Just informative ways to fabricate junkyard finds instead of doing Pimp My Ride.

[@Stackali]

except they did it wrong. no fishplates. just a straight weld.

[@Lashazior]

@@Stackali don't care bro it's a tv show this won't be a heavily utilized vehicle.

[@Jaz_3001]

16:56 this doesn’t look normal to me; is the chassis supposed to bend like that when you lift it with the floor jack?

[@vxnova1]

I didn’t notice it bending, maybe a little flex from side to side which would be ok, I don’t know why they didn’t run the 4 x 2 box metal all the way forward to the cab though, they only overlapped by a few inches,

[@racekrasser7869]

I didnt see any bending....just the leaf springs moving was all

[@Jaz_3001]

It might not actually be bent; I’m watching this on mobile, so sometimes things look a little abnormal on my screen

[@Thraser999]

@@Jaz_3001 Watched it on my PC, it did bend...

[@THROTTLEPOWER]

Very cool !!!!!!!!!!!!!!!!! 👍👍👍👍👍👍👍👍

[@Shane-Singleton]

Carcass is going to take on a whole new meaning if somebody is foolish enough to get behind the wheel of this thing, load it up, and try to drive it with that back-half on it.

[@Valdemar-Perez-III]

Ok how would you have done it then?

[@mikecabot1617]

Frame is an alloy which is heat treated. Welding on frames changes structure. That HSS tube is not nearly as strong. The splice to original frame also has a procedure. Not to weld vertically.

[@colinrob6662]

I fully agree that thing is going to snap in half, it's been welded with hardwire SMH!

[@darrinbunston5932]

I would have went after some 8" Channel iron blending the two together Diamond plating the 2 frames together

[@superdad2150]

Let's listen to their quote the original frame had a kick up to clear first suspension travel oh, let's just put a flat straight piece in place of it where the original kicked up was definitely some Jerry rigging going on here

[@fordnut4914]

The guys at Pakistani trucks be like dude your making this frame forming way more complicated than it really is.

[@deanbaker6606]

You need the box to frame where the new frame meets the old frame that makes it Bulletproof

[@ItsDobbs]

16:33 ... the bolt bottoms out. "THATS PERFECT!"

[@justinballard7242]

It just wasnt lining up with the hole on the other side

[@2000blackstang]

Haha yea that's funny! And they claimed it was perfect! Lol

[@jryer1]

Nice fab and MIG guys!

[@richard_lerma_jr]

Thank you bro's

[@heartoftexasbarnfindsandcl5193]

Cool Build

[@lunchbox2784]

What type of steel was that homemade channel made out of? I’d be curious if it has at least the same properties as the original frame, especially on a tow truck with a heavy service life. If not, it wouldn’t hurt to box it in. A frame failure could be devastating.

[@baileysconstruction7898]

I’m more worried about that straight weld line. A straight weld line like that is weak

[@lunchbox2784]

I agree. Needs a diamond fish plate. The bent channel didn’t look very straight/flat. Maybe it was the camera angles. Looks sketchy for some reason.

[@reweydewy]

I doubt this truck will actually be used heavily if at all

[@lunchbox2784]

@@reweydewy true. I guess this truck will be more of a novelty than anything. This still doesn’t send a good message to the novice DIY guy trying to perform a frame repair. I hope people do more research before attempting this themselves.

[@lunchbox2784]

@@bigboreracing356 that’s a 3F weld, not 3G, if we are talking about test positions with what I assume is AWS D1.1 in your reference. The GMAW vertical up progression can work as long as it’s set up with a true short-circuit transfer. A weld procedure is possible for this, but not easy. Gas-Shielded Flux core (FCAW-G) is an easier and better option, though. FCAW offers more penetration and is easier to weld out-of-position (3F, 4F). Using a solid-electrode “bare wire” (GMAW) would work fine in this application, but would be better with a fish plate of sorts. It also helps get the weld positions into more of a 2F or 4F position, depending on the angle of the fish plates, making for an easier weld with better chances of getting adequate penetration. 2F in a spray transfer offers a substantial amount of penetration when compared to short-circuit or globular transfer. 3F short-circuit GMAW is not an easy weld to get adequate penetration, and 4F isn’t much better. SMAW would be a good option as well.

[@PaulJersey]

I am a structural engineer not fish plating the existing frame to the new frame goes against everything that I was taught about steel connections. The shear stress under a heavy load could break that welded connection. On a practical basis that old junk will probably never be used for any heavy towing anyway.

[@PaulJersey]

@@bigboreracing356 Because without an X-ray there is no way to determine id the weld is 100%.

[@PaulJersey]

@@bigboreracing356 To be fair you would not have to fish plate it, if the weld was done right.

[@louieallen6964]

It wasn't butt welded. It was slid inside of the rails of the truck and if welded on both ends it should be fine.

[@mrjeep881]

I would definitely not tow with that the metal is not heavy enough. I have run tow trucks quite a bit and seen the factory frame crack and bend under the pressure

[@ypopnun1003]

Your shock mounts at 90 degrees off at the top and they will break the top of the shocks.

[@danf4616]

FINALLY they are rebuilding and saving something, instead of just trashing classic vehicles and making them less than they were. At least, I hope that's what they are doing...

[@athonyvaloni7091]

Stupid question but why not just cut the back half from another truck ?? There was a whole line to choose from in the opening scene ...

[@DEATER155]

I’d consider talking to dustless blasting and have them take all that rust off the bed and repair some of the structural points of the towing arm and ect it would make it 100 times easier and cheaper than taking it all apart and then having to take it piece by piece to a blasting place

[@toosunakabooma1213]

You guys have me digging out my straightest straight things. I got a 30 gallon barrel full of grippers and biters that were holding up a rabbit wire Tomato bunker that produced a quarter bushel of fruit I could have bought for less in Downtown Tokyo.The tools are responding to my secret recipe of anti oxidation immerserion ressurection protocol and I'm forecasting a better than 50% positive outcome on usable hand tools....In short this video slapped me awake to chase down the "I can do this!" guy that this covid pandemic scared away.Funny how life saving inspiration finds a place to just patiently wait for some of us to simply trip over it and recover from the impact trauma. I was lucky.I fell on my head.. Blsssings to you and yours! BUCS BY 12. UPDATE!!! Screw these assholes that have all of these opinions but no tact or consideration as to how they share it with others.The only stuff I've learned in life worth sharing were based on fails and what path it took to find solid solutions.So exactly what makes any of us worthy of disrespecting an honest effort when their wisdom came from the solutions they scratched and clawed out of the grease and mud,looking for the stuff to take another swing at it.We are above this snide arrogant bullshit.Anybody care to share some of their" Ye haw! this is gonna change this whole freaking build" moments or talk shit about how they're the jncarnation of Lil John Buttera? Grow the Freek up

[@avistaman8484]

love the work

[@Hissmannen]

Great job on a crusty but cool truck. And i’m so glad we use metric where i come from.

[@micahdeboer9877]

That old to new frame joint should definitely of been fish mouthed or had a diamond plate put on it. I wouldn't trust that on a car let alone a tow truck

[@chesspiece81]

All the shots of just your hands at 5:24 looks like Ricky Bobby finally found something to do with his hands.

[@darrinbunston5932]

My concern here is the way you guys built your frame using Tube steel which will eventually rust out and then the homemade Channel you put the tube steel in you didn't cantilever it even though gusseted between the two you didn't cantilever it and that's going to make for a weak spot

[@1SixpenceFan]

The junk yards that I have asked in North Carolina about buying the whole vehicle, said they couldn't do it. I don't remember if they actually said it, but they implied that it was against the law. I asked about a 1993 GMC Typhoon in a pull a part yard, two weeks later it was gone. No vehicle leaves that lot that fast.

[@MoparMan-ff8fb]

Looking good so far . Hopefully all the old same and new frame gets treated to anti rust coating

[@Dallas.Sterling92]

I think I would have made a little bit differrent shock mounts that would turn 90° the other way to allow for more axle movement.

[@robertweitlauf4653]

my brain hurts. one thing for sure, someone was paying attention in geometry class.

[@boxerfan2]

If they are a little off on cutting and measuring I can imagine going through tires from misalignment.

[@landonwoods917]

You guys should do a 80s Toyota 4Runner or pickup with a 6 inch lift and 35s

[@jusinhelman6011]

Really nice job guys

[@vinnyfrench8108]

Down bead meaning is starting at the top and going to the floor, cracks fast no strenght to weld joint. vertical welding is floor to top all the penetration is being put into the joint itself making it a strong joint. For people who don't know even the welds look different.

[@johnleca]

Great video. Love it. Wish I had those tools.

[@dazaspc]

Awesome job for an old truck. I would be a little concerned doing this on something more modern as they frequently will use High Tensile steel in a chassis.

[@dazaspc]

@@bigboreracing356 In the old days rivets were usually used on special steels.

[@masoncarver460]

Think i woulda just found another reg cab long bed frame back half isnt rusty but front half still suffers from same levels of rot and rust as the rear did wouldnt be suprised if the frame ends up cracking at the steering gearbox one day because of rust

[@walker7155]

I’m a welder, building heavy equipment for miners. HOW DO I GET A JOB LIKE THIS!

[@ericwilkes238]

Could that be welded with 7018 stick.because that's all I have.

[@georgepmr]

Best show since Shady Tree Mechanics! lol

[@jleote]

The C Channels arent bent to the exact 90s. Theyre off. Makes my OCD go nuts lol.

[@toosunakabooma1213]

My girlfriend has crooked pictures hanging in the hallway.The wedding is off....Its the civilized thing to do...

[@jleote]

@@toosunakabooma1213 hahahaha

[@georgesviderski2469]

Mig weld is not strong. Arc welding is way better. They didnt even chamfer the cross members before welding. This frame will break right after the weld. A frame not only flexes, it twists alot. If you dont spread out strength over a far distance it will fail. This is how you join the two frame halves, use a Z joint like iron workers use on I beams. then cover the length with a separate C channel about 2 feet long fit inside the existing frame joint , then weld the C channel with interrupted welds about 1/2 -3/4 inch long. Along its ends. You should have used 1/2 inch grade 8 bolts used with a welded spring perch all four perches

[@jasonholloway2476]

This episode makes me wish that I would have paid better attention in geometry class 🤓

[@austindillard8936]

I feel like a dunce with the math they're doing.

[@jasonholloway2476]

@@austindillard8936 Obviously these guys have done this kind of work before, they have professional level equipment, a budget to be envious of, a lift that most Joe homeowners wouldn't have in their garage, and they're getting paid to do this... The way that he made his C channel, I'm impressed with the know-how. I'd like to be at his level one day.

[@king0cans]

This episode makes me thank God I don't live in Tennessee.

[@Thraser999]

@@jasonholloway2476 There's still a fundamental flaw to how they did it, making it lower un height, and with how they welded it together, it makes for a weak structure...

[@jasonholloway2476]

Other commenters have said that as well. This better be a truck for show only, not real use

[@TylerJohnson-wp2qf]

For a tow truck I'd weld and then drill through the frame to bolt down thag shackle

[@toosunakabooma1213]

Decent of you to share instead of criticize

[@bigredracer7848]

565👍's up guys thanks again for taking your time for us all to be with you

[@matthewchase2512]

I I love that truck !

[@supercharged65]

So the frame decided to stop rusting and rotting out right at the back of the cab?

[@garyhoelting5994]

the gap between the cab and bed allows rain to get to frame,and rust it there,my 79 gnc tow truck is bad there,they sit outside in the elements for years

[@Mjc103]

20:23 the flex in their 3/16 mounting plate is sketchy AF.

[@kamalmasbahi8770]

Good Job 👍

[@andondimitrov3895]

good job.....!!!

[@theupscriber65]

How much does that wrecker body weigh? You should build a new one from polished aluminum diamond plate so it looks like a wrecker body but mount rhe tow boom to the frame directly. Or you could just buy an aluminum wrecker body.

[@imranabbasi7871]

Good luck 👍

[@calvincrews3885]

That’s a great new back half but why not add a fish plate so it won’t split in half back them GMC PD series Grumman Flxible ADB Buses and MCI 96A3 they had Cracked Frames back then

[@bartgoins1782]

Your little 3 or 4 inch overlap of new frame to old isn't good enough. There also should have been horizontal diamonds welded on to reinforce the spice better. If that truck actually got used as a tow truck, that splice would not hold up.

[@bartgoins1782]

@@bigboreracing356, nope, I've always had better sense. However, I have seen several welded that way that didn't hold. Any other "good" questions?

[@bartgoins1782]

@@bigboreracing356 whatever. I've seen that same type of repair break several times from abuse vehicles go through, and I wouldn't bet your grandchild's life on it, but you go ahead.

[@bartgoins1782]

@@bigboreracing356 and you think the welding in this video will hold, and I think you're wrong.

[@bartgoins1782]

@@bigboreracing356 But you're willing to defend it, because your "quality of work" would not fail. Since you didn't do this welding, your whole argument is moot.

[@Stackali]

@@bigboreracing356 and what is wrong with diamond plates or even fish plates? it can only make it stronger and doesn't hurt anything. why not make it as strong as possible? its just a bit of extra metal, not even that much and some extra welding. this guy cut a jeep in half and welded fishplates and diamond plates. kzbin.info/www/bejne/r6LLZIOYpNCkgqs

[@larrythomas3624]

You know there is such a thing as a C.W.I., right? Certified Welding Inspector is a thing..."Well, I've inspected welds" doesn't equate to an inspection certification either, as in advanced metallurgy, metal compositions including carbon content etc.,and that cert. is no joke. That's a certified welder with at least 5 years on the job then taking a hellish test that takes literally about a week to get through with a first time passing rate of about 20%!! Meaning 80% fail. I'm not downing anyone, just sayin. And a structural engineer could weigh in too!

[@shadowopsairman1583]

About time they did a real project instead of butchering a 3rd Gen F Body or making a TB ugly. The only Problem is I would of pulled the body, trans, engine, cleaned the chassis up, repaired any of the body, rebuilt the engine with vortec heads with a common rail fuel injection system with a 6 speed manual or automatc. Or did a fresh carb overhaul with a 6 speed manual. I would of put in the frame with the proper well over the axle like the original frame. Also I would of kept the new frame dimensions exactly the same as the old and added 3 foot box splices that fit the inside of the frame all welded to add strength.

[@CurboroughSprinter]

Long live the metric system! 😂

[@shane7875]

They didn’t even do any fishplates at the joints. Sketchy

[@CJLeTeff]

That chassis over the axle should be taller. You can tell this is for show only, and not work. Still nice job regardless.

[@threeangelsdiesel]

Well the fact that they are putting in an automatic with a 480 mechanical lift shows its for just a show

[@royscarbrough3589]

They went from C channel to tubing-I think they actually made it much stronger.

[@supersport1986]

My thought is I think I would have felt better if they would have overlapped the tube on to the c farther but overall I would say it should be pretty tough

[@Stackali]

they also didn't do any fishplates, just a straight weld. definitely gonna break in half.

[@flyonbyya]

Based on the grill and emblems...it’s not a ‘77, but rather a ‘73 or ‘74

[@stevezack6077]

Amazing what you can build with 2million in equipmenr

[@kenbaker1353]

What about the front all the Rust

[@yabasta13]

Ok mad respect for that math game

[@goat4298]

As long as that chassis, suspension, and drivetrain or structurally sound, I'd keep the patina on the body.

[@speedfreaksracing7361]

Hell ya looks great

[@محمدياسينالخطايبه]

amazing

[@nattydreadlocks1973]

Ain't many cars on the road you can tow with that.

[@Sugiemonster97]

It'd be cool if they did a burn chevy silverado off copart

[@SlipperyDucky]

Metric so much easier than fractions 🇨🇦

[@travissawatzky9924]

Fractions are extremely easy to convert to decimal points

[@tomnekuda3818]

Damn, you guys do some good work!

[@cap1398]

I think new Chassis not strong because oem Thick and one Piece Chassis

[@kenbaker1353]

I definitely wouldn't put the Wrecker body back on

[@kenbaker1353]

A frame off restoration would be better

[@ethansprofile6670]

Mader never looked so good!

[@yungkidnf]

Came for a truck restoration, but apparently stayed for a geometry lesson 😐😐😐

[@georgesviderski2469]

Tow truck with a small block is wothless . Its all for show. Big block 454 will run circles around it and make you money for years to come

[@ScratchandDentGarage]

Not necessarily. When I was a little boy, my papaws friend started a wrecker service. Early on in his business adventure, his wrecker blew the original 350 sbc up. Papaw pulled his own tow truck into the the garage, removed the engine, pushed it out and brought his friends in and gave him the motor. It lasted for years and made him thousands of dollars, if not hundreds of thousands. It’s not all about the engine, it’s gearing from the transmission and rear end as well.

[@TheAleutiansolution]

These guys have obviously never seen or heard of a radius gage. Would’ve taken all of that guess work out of the equation.

[@jeffreyboarman4032]

Should have primed it and painted undercoat

[@jeremybarnes5320]

You are absolutely wrong about the spring hangers. 1/2 ton and 3/4 ton (10 and 20) measure the same from leaf spring to leaf spring packs. 1ton or 30 models are narrower between leaf spring packs. This is for the commercial options. Its ridiculous. GM should have made them standard like was started in the obs. Plus you didn't overlap far enough into the old frame with the new section.

[@patricksaylor1477]

Just get another frame it's cheaper and that now will not pass a CDL inspection

[@TheRoadhammer379]

a CDL inspection? A commercial driver's license inspection, wtf are you going on about? A state motor vehicle inspection is not a CDL inspection, lmfao

[@patricksaylor1477]

@@TheRoadhammer379 when I took my CDL the instructor had me get under the truck and inspect everything and nothing is good on an inspection if you do not word it correctly you failed and if the frame has been bent or welded they will fail your vehicle they even failed the vehicle that we took because the driver side door had been replaced and the body shop did not replace the vehicle information sticker in the door jam it failed so we had to go the Dodge house and get it replaced $300.00 bucks later I finally got to take the driving part of the testo and being a tow truck has a hole other set of rules that is what I and dot is saying

[@patricksaylor1477]

@@TheRoadhammer379 if you have not applied for a CDL on the last year you will have no idea what I'm talking about sorry

[@Happyfacehotwheels]

It's the same when you're taking a driving test. They inspect the vehicle to make sure they don't die while you are driving..