I have a 1970 Ford F100 Sport Custom w/ 302/C4 which I work on between home improvement projects and range time. I plan to get a Hobart 140 to help to perform the work in the upcoming months. So, up first is the frame which the previous owner cut to install power steering in the truck with a Bendix gear box. Here is what I have...



Frame @ Steering Gear Box

Can I just get some steel plate of the same thickness and either overlap the frame or butt weld it in the hole? I would clean/degrease the area and "square-up" the edges of the previous cut prior to welding. I am replacing the Bendix box with a correct Ford steering gear box.

For the second one, here is some pics of the passenger bedside which the previous owner had some damage from an accident.



Pass. Side Bedside

Pass. Bedside

So, I see two options here depending on the damage. 1.) Dent pull area with slide hammer and finish or 2.) cut the area out and replace with replacement panels, i.e. for the JY and finish.

I am looking for any suggestions, because this will be my first adventure into body work. _ Tony

 

The frame can be fixed, but you are not going to do it with a 140 Hobart welder. You need to go at least 6 inches each direction from center line and plate it. In the center of the plate on both sides drill some 1.5"-2" holes that land on the existing frame and weld the plate to the frame. I suggest 1/4" A36 and full bevel for the plate. Proper frame repair will look like this. I wouldn't do anything less. I run .045 wire 160 amps. If you have the ability or know someone you can also do spray arc transfer welding which I do on heavy frames or equipment. It's a factory welding technique and works very well.

Not my photo, but same method I use. Very common method.

 

Thanks, ford390gashog. Here is some other pics of the frame area in question...




Frame @ Stg Gear Box

The area of the repair will be right @ the mounting point of my power steering gear. So would you go with the same repair that you mentioned? _ Tony.

 

Holy crap, that frame is so weak and unsafe it's a miracle it hasn't collapsed. You need to repair all 4 sides and make sure you are capable and comfortable being able to do the repair. There will be a decent amount of overhead welding and it isn't easy. Make sure you prep and clean everything prior to welding and preheat and clean again. Preheating the metal pulls extra oils to the surface because that frame looks caked in grime.