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'79 928 Euro 5 Speed
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'79 Cracked Frame Fixed
Just posting some info from a recent fix. I'm not entirely sure when the frame cracked but I started to notice the car pulling to the right. It eventually got real bad so I decided to pull off the caliper thinking that maybe it was sticking. It was just fine and as I put it back on I noticed this:
 On the back side:  Where the front of the frame ties into the cross member in front:   Beaten into submission, cleaned up and ready to weld. I used some tie down straps to make sure the frame was pulled in tight before I welded:     After welding up all the locations plus the seam across the bottom, I fabricated a stiffener plate out of 1/8" thick steel. I used a 115V flux core welder. Not the greatest, but everything tied in well.  I was mainly interested in the functional aspect of the repair so I am quite happy with how it turned out. I just sprayed underbody coat on everything when I was done. Didn't need an alignment either! Car drives straight again. Back on the Road: 
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'79 Porsche 928, '00 Porsche Boxster, '86 Porsche 944, '04 BMW Z4 '77 Fiat Spider 124,'07 Chevy Suburban LTZ '83 Jeep CJ7, '06 Harley Sportster |
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06-12-2014, 05:15 PM
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928: Serial Enabler
Join Date: Sep 2007
Location: Elkhart, Indiana
Posts: 2,929
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Crazy bad failure, impressive repair. That right there is awesome.
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84,85,86 928 cars |
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06-12-2014, 05:30 PM
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I like to see a total do-it-yourself repair - nice job
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84 928 S - SOLD 2012 Cayenne S |
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06-12-2014, 06:05 PM
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Kool
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Day-um Rupesy....that is wicked. What do you think caused the damage? Gives me an extra hope boost for #30....great work!
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Ron 1978 5sp (#30) project-Wreckscue, 1979 5sp Euro Project 1982 5sp resto project, 1985 Auto S3 1984 Parts car (the fire car) 1987 s4 (parts, or maybe project) (Yes, I now have 4 project Sharks) |
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06-12-2014, 07:05 PM
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Well done! That was one big crack...do you think it was in making over many years or a recent catastrophic failure?
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George in Indiana 928 Weissach #153 Cayenne S |
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06-12-2014, 07:10 PM
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Petie3rd
Join Date: Jul 2000
Location: Philly PA
Posts: 4,528
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this is more common that you might think,
the area above the crack can fill with water and then a rusted area will form and then the crack starts. BTW a very nice repair you have done, you may be able to buy the correct body shutz instead of the spray on autobody undercoat
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^^^ Stan ^^^ 2019 BMW K1250 GS 2016 HD RK 1988 S4 Auto , Elfenbein Perlglanz, Pearl Gray 1982 5sp Met black and tan sport seats Last edited by Mrmerlin; 06-13-2014 at 11:18 AM.. |
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06-12-2014, 07:42 PM
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928: Serial Enabler
Join Date: Sep 2007
Location: Elkhart, Indiana
Posts: 2,929
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Mark Anderson has posted about seeing front frame failures
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84,85,86 928 cars |
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06-12-2014, 07:42 PM
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Impressive!
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1984 Porsche 928 S (US) 2002 GMC 2500HD Full time Nerd |
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06-12-2014, 08:42 PM
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1979 5sp 928 project
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Great repair and good looking shark too!
Way to keep her on the road.
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1979 928 5sp project 1984 928S 5sp black on black |
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06-13-2014, 10:33 AM
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Registered
Join Date: Aug 2012
Location: Philadelphia Area
Posts: 3,672
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Nice repair work Rupesy,
Beautiful 79, odd that this happened with 85K miles? Braking forces on the lower wishbone probably caused this. Maybe some have manufacturing flaws. Did you look closely at the upper wishbone on that side it may have taken a beating. Matt
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Matt Mariani @the_r_institute Authorized Retailer FIKSE Wheels Mod Italian Wheels Maxilite classic wheels Last edited by The Fixer; 06-13-2014 at 02:52 PM.. |
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06-13-2014, 02:40 PM
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'79 928 Euro 5 Speed
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I'm not really sure what was the cause as I am not an extreme driver. From what I read, it looks like maybe the spot welds on the lower seam come loose. The reason I think it is a big as it is is because I drove it so long before addressing it (about 8-9 months). I am ashamed! At first it was only a slight pull and I just thought it was a caliper. Then one day it was noticeably worse but I kept on trucking. I stopped driving it when I saw how bad it was. The repair only cost me one day of my time and about $20.
Next issue is the AC cause its getting HOT in Texas!
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'79 Porsche 928, '00 Porsche Boxster, '86 Porsche 944, '04 BMW Z4 '77 Fiat Spider 124,'07 Chevy Suburban LTZ '83 Jeep CJ7, '06 Harley Sportster |
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06-14-2014, 03:51 AM
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'79 928 Euro 5 Speed
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Also, miles are unknown. It has 65k on the dash with broken odometer. I've had it a few years so I took a stab at a number. In reality, it could be over 100 but who's counting??? LOL!
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'79 Porsche 928, '00 Porsche Boxster, '86 Porsche 944, '04 BMW Z4 '77 Fiat Spider 124,'07 Chevy Suburban LTZ '83 Jeep CJ7, '06 Harley Sportster |
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06-14-2014, 03:54 AM
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Registered
Join Date: Aug 2012
Location: Philadelphia Area
Posts: 3,672
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Well regardless of how and why, your car is really beautiful.
I like the early cars in white, very nice. Front end looks perfect! [/QUOTE]
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Matt Mariani @the_r_institute Authorized Retailer FIKSE Wheels Mod Italian Wheels Maxilite classic wheels |
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06-14-2014, 11:05 AM
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Network Native
Join Date: Jan 2007
Location: SoCal
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I'm thinking road obstructions, speed bumps, curbs, potholes, but not braking, not enough force.
Amazing what those flux welders can do for so little $$$. |
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06-15-2014, 03:40 AM
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Registered
Join Date: Aug 2012
Location: Philadelphia Area
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[QUOTE=Danglerb;8117008]I'm thinking road obstructions, speed bumps, curbs, potholes, but not braking, not enough force.
Metal fatigue: is the progressive and localized structural damage that occurs when a material is subjected to cyclic loads. It is most likely that some 928s have a manufacturing flaw in this location. The force exerted stopping a fast heavy car over and over again on a daily basis for 30 plus years is much more likely the cause of fatigue imo than parking to close to a curb and/or running through the occasional pothole.
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Matt Mariani @the_r_institute Authorized Retailer FIKSE Wheels Mod Italian Wheels Maxilite classic wheels |
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06-15-2014, 07:12 AM
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Kyle C
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Very odd indeed, really nice job on the patch-up though!
I had noticed that my lower control arm mounting bolts, specifically the two front ones, had some corrosion present when I overhauled the front suspension. I think there is an opening on the inner side of the frame near where the upper control arms bolt in. So it wouldn't surprise me if water/moisture gets in there are causes problems. But I don't really see any rust present where your frame cracked?
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1974 911 1978 928 5spd hillclimb special 1984 928S 5spd, 1986.5 928S auto 1983 944, 1984 944 track car 1995 Saab 900 S, 1997 Saab 900 Turbo, 1999 Saab 9-3 S |
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06-17-2014, 10:47 AM
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1979 Porsche 928 4.5L
Ford F250
BMW
Fiat
Ford
Chevy
Chevy
TBA
Whitey
Pontoon
# 153
BluTwo
