11/30/2024
This job turned out to be more complicated than we anticipated, but in the end it actually came out perfect!
1988 Chevy Monte Carlo with a rotted-out steering box that was no longer functioning properly (this is a common problem in older "G body" cars).
Many companies sell aftermarket "caps" that fit over a rotten section of a car's frame rail and can be welded in, sort of like a brace. In this case though, they only sell the whole kit ($$$) to repair the entire front end, and you can't buy just the one piece for the steering box.
So, unfortunately we had to advise the customer to take his beloved Monte Carlo for one last farewell drive down to Dirke's salvage yard, and kiss it goodbye forever. :(
Gotcha!
Vaino's Automotive & Welding to the rescue yet again. We just went ahead and fabricated the one section of frame rail cap ourselves. We do these things the old fashioned way: First, we welded in 1/4" thick, 2" steel squarestock as a backbone to reinforce the frame on the inside, and ran 1" steel roundstock in between the frame to prevent it from crushing when you tighten up the steering box. Once the frame had been reinforced and stabilized, we created a mold of the old steering box area using very thin sheet metal. Using that mold, we then hand-fabricated the actual frame cap with 14ga steel sheeting, an anvil and hammering, heat (torch), and a metal bending device called a brake. After the piece was finished, the inside was treated with rust prohibitor and undercoating, and then welded it into place (after that, we treated the outside surface as well). Finally, everything had to be measured and ensured to be exactly in the right place according to factory specs so that the car drives straight and is able to steer freely (it was, and didn't even need an alignment after the test drive!).
Our customer was very pleased with the end product and so happy to KEEP ROLLING in his favorite ride! As for us here at Vaino's...just another one for the books.