New Issue for Me... cracked repair weld on trailer

[WhiteRice]

So, I was rewiring a loose connection when I found what looks to be a repair weld on top of the 2x3 beam that my axle springs mount to. This weld is now cracked all the way across the top and is now a split in said beam. This is a galvanized trailer so my question is can the repaired weld be repaired again? This beam really can’t be replaced and I REALLY don’t want to buy a new trailer. Anyone feel confident in having repairs like this made to their trailers?

 

[MTboatguy]

It can be repaired by a shop that is equipped to weld galvanized metal which is very noxious if you are not prepared, it is probably going to be more expensive than welding on normal untreated steel, I have welded galvanized in the past, but I won't do it any longer, the safety precautions you MUST take are expensive.

Making a determination would be much easier with a couple of pictures.

One thing you want to take into account, if it split, then there are other areas in that trailer that are most likely weak making them prone to breaking as well.

 

[Scott Danforth]

anything man made can be re made.

grind the galvanizing back, weld it up, apply cold galvanizing, go boating.

 

[WhiteRice]

Here’s the best pic I could get with the boat still on the trailer in the dark. The beam is a 2x4 "C" channel (mistake calling it 2x3 earlier).

 

[dingbat]

Grind it out and weld it. A decent welder could do it with his eyes closed and one arm tied between his back.

The zinc issue is way over blown. Along the lines of everyone will die if you ride in the back of a pick up.....lol. Been there, done that, drink milk and go back to work again the next day.

 

[Scott Danforth]

that has been repaired at least once, if not twice.

so now it will be repaired again.

 

[Maclin]

Looks like it may need some plating added to reinforce it this time.

 

[M2HB]

Grind the metal bare and one pass of 7018 top and bottom and problem is solved. You need to watch for other cracks. There is a reason that cracked. Obviously the previous repair was substandard. I don’t think you need fish plates in this case. You just need to have competent welder do the work.

That cold formed trailer was common years ago. You can tell by the wrinkles in the steel. They usually work quite well. It was an inexpensive way to make a trailer without all the cuts and miters to make it with straight pieces.

 

[MTboatguy]

There is no galvanization left in that area it has been repaired at least once before, grind it clean and weld it up again. As far as welding on galvanized metal being an overblown threat, no it won't instantly kill you but long term exposure can cause medical problems just like any kind of fume or particle exposure can.

Just to be upfront, I have done it without a respirator in my younger days, and I rode in the back of a heck of a lot of trucks when I was growing up and I can't begin to tell you the number of times I have been exposed to asbestos in my life, none of it has killed me yet. We just have more information available to us now than we did then.

 

[AlabamaNewbie]

The weld didn't penetrate, so that's why it cracked again. Who ever did it was a novice welder and was welding too cold and fast. You can tell by the lack of a bead pattern (along with that horrible splatter) that they either didn't know how to weld properly, or care too much. Make sure your weld penetrates properly and it will be good as new.

And yes, all of the galvanization was burned off in the first repair, so no worries about that. Even if it hadn't, the amount of zinc you'd be exposed to in that small of an area would not make you sick. If you did it a lot, then you'd want to take precautions. But this isn't that. Usually I would always suggest erring on the side of caution, but honestly - the zinc thing is so misunderstood. Zinc bonds with oxygen to form a gaseous zinc oxide fume. Zinc Oxide is non-toxic - its used in diaper rash treatment for pete's sake! The fumes, in abundance, can give symptoms similar to the flu, but they pass. I've welded galvanized metal a good bit, and I've had zinc flu. It sucks, but its not deadly.

 

[WhiteRice]

Thanks for the info guys. Now I just need to find someone with the skill to do it right. I appreciate it!

 

[M2HB]

A competent welder could do that entire job in about 30 minutes. It takes more time to prep the job than the welding takes.
i prefer 7018 because you can get good penetration. On thick steel you would grind a bevel, but this steel is so thin that it isn’t necessary. I would weld the bottom side first and then weld the top with extra current to make sure I got full penetration.
i have a Millermatic 350P pulse arc mig welder, but I would still weld it with 7018.

 

[Maclin]

In my head I keep going back to what caused the crack to start in the first place. Might be worth the gusseting if the forces re-appear.

 

[WhiteRice]

I hear ya. I have someone coming to my home next week to repair it properly and is going to reinforce all three sides and the inside of the crack with aome plate steel (fishplate). I wonder the same thing about “why” but I’m not in a position to spend $1800 on a new trailer for a boat that is worth $5k. That will just have to come when I get a new toy