Check your spring pockets for cracks.....

[BruceTS]

During Locos Mocos NV2007 run where Lance wrecked his rig, I had my share of problems.

this is an image of the spring pocket torn away from the frame
http://bruce.calrockx.com/4runner/misc/spring plate.jpg

As you can see it torn out a large section of my frame as well
http://bruce.calrockx.com/4runner/misc/cracked.jpg

Looks Ugly
http://bruce.calrockx.com/4runner/misc/cracked2.jpg


As for the fix.... I welded up the frame and plan to make new spring/shock plates that are bolt in design, so I can easily make future changes. For now I temp welded the plate in till I get them built.

This isn't the first time I've seen this happen. FearToy's rig had a similar failure. Now how does this occur, simple.... a poor design allows the plate to flex along the weld toward the front. Eventually causing it to break away from the round tube. Once this happens it'll quickly tear away from the frame. My right side show the same type of fatigue, a hairline crack is starting.

I knew that this would eventually happen, but wasn't too worried, since I already had a new design in the works, which will allow me to run longer shocks, without lifting it any higher.

[Marc P]

Hey Bruce that should work for 2nd gens too....that is what I was thinking about. I wanted to do some sort of shock relocation bar, but did not want to inboard my shocks at all.

http://www.imagestation.com/picture/sraid225/p311afd1220daeb52c1c6eb5e3a04f5bf/e9d22db0.jpg

[p nut]

Good info. I guess that changing out that top shock nut won't be a real PITA anymore. :D

[BruceTS]

Here's after I welded the frame back , the plan it to build a wrap around spring pocket assy, so I can spread the load over a larger area.
http://bruce.calrockx.com/4runner/misc/welded frame.jpg

The circle is where you should inspect your frame pocket for hairline cracks, if the paint is chipped, most likely there's a crack.
http://bruce.calrockx.com/4runner/misc/location.jpg

[Lee]

thanks for the info bruce, ill check mine out :thumbup:

[Euphorickaty80]

Wow....thats not good....Will that permamnently weaken the frame or should the weld fully restore the strength?

[MTL_4runner]

Wow, that is downright scary! Looks like you welded the crap out of it on the one you repaired so that ain't going anywhere. I'll be curious to see what you come up with as far as a new design to prevent future issues.....might even start a trend. :thumbup:

[BruceTS]

I'm sure the frame is weaker, since all I did was weld back the pieces that tore out. Once I build my new frame plates, they will wrap that area, which should make it stronger. Fortunately I have a spare frame to build from, so after I get the current bumper I'm building finished, I'll get to work on it. For now no wheelin.........

[d0ubledown]

wow..thats a new one. never thought that area would be a problem. down right scary...were you still able to drive like that? or were you pretty much bottomed out? nice fix...looking forward to seeing how you plan on beefing that area up.

[Lee]

yeah how did you get off the trail?

[BruceTS]

Had no choice, but to drive it out along a wash boarded dirt road for 40+ miles......

When it busted it took out the ABS sensor wires and the harness going to the e-locker. I was lucky the rear brake line didn't get damaged, but it was pinned between the body and broken off plate. You can see in the pictures where the plate was pounding against the body. I still had about 2" of suspension travel.......

http://bruce.calrockx.com/4runner/misc/lowrider.jpg

[Lee]

hahah you and i both have the door part of the rear flare ripped off :D

but mine is on the pass side :laugh:

[neliconcept]

might just have to go check mine now, that scares me.

[BruceTS]

hahah you and i both have the door part of the rear flare ripped off :D

but mine is on the pass side :laugh:



Nope mine are still on, I just cut the lower portion off, for clearance

[Lee]

oh, hah, it looks off... my bad :)

[MTL_4runner]

Looking at the pic with the truck covered in mud I couldn't tell either. :laugh:

[ecchamberlin]

Wow Bruce that is not so great.

I am not sure all of the people here understand how hard you push your rig. I have been pasenger for the beatings and have also seen it from behind on numerous runs. That 3rd gen gets used and then some and let me tell you it is fun as hell to watch.

My point is that most of us will never have to worry about this happening to us.

Knocking on Wood now. LOL

[BruceTS]

The problem is a design flaw, my rig isn't the first this has happend to. Yes I push it hard and have compressed to the bumpstops on many occasions, but it was going slow on the washboarded roads following Lance's rig out that it finally broke. The constant up and down, flexed the plate enough to break the welds. A simple way to think about it, is if you to take a flat piece of metal and bent it back a forth till it breaks in two. The top plate isn't ridged enough and does flex, over time, I'm sure this will happen to others.