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coach frame cracked

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Jeri Browne:
We were having our 1999 Beaver Patriot coach serviced and asked for help identifying a knocking sound at the back roughly between the bathroom and bedroom.  The service tech looked underneath and found the frame cracked in the relative position of where the cross piece bolts to the frame rail. 
they did not want to attempt to fix it.  They had no referral for us.
We went to a welding company as we have been unable to find a frame shop in Montana.
The welding company said they saw the crack and it was a major project to repair requiring the engine to be removed before the work could be done.  He felt it was a poor design in the first place.  He also felt the cost would be greater than the
coach 's value.  He also declined to do the work.
Both places felt it was unsafe to drive.

Help!  What other possibilities might we have?  Who should we be asking for help?  Has anyone else experienced a cracked frame?  Where do we find a frame shop?   Your thoughts and experiences please.
Thank You
Jeri and Corb Browne
Great Falls, Montana

Steve Huber Co-Admin:
Jeri,
Did you check with Specialty Iron Works in Great Falls? They did some frame work on our toad back in 2015 and seemed very capable and honest.
Steve

Joel Ashley:
There are others here with more expertise than me on frame dynamics, and they will likely offer input.  But if it were me I would try to get some good photos of the crack with clear perspective on its location, and then call Henderson's Line Up in Grants Pass, Oregon.  It may be that you'll have to have it trucked to them or another capable shop, but chassis technicians don't come much more knowledgeable than Henderson's.
tel:(541)326-4033

Joel

Carl Boger:
Jeri,

My coach also had a crack where the strut rod held the rear axle from shifting side to side. I am not a frame expert, but here is what I did and mine has held up well for over 5 years now.

First I drilled holes in the frame at the end point of the cracks.  I also drilled a series of holes around the perimeter of the damaged area. I welded up the holes where the cracks ended from inside and outside.  I cut out a piece of 1/2 inch thick steel that covered the damaged area and matched up the strut rod bolts and some of the newly drilled holes.  I got all new grade 8 bolts of the correct length and torqued the 1/2 inch plate down tight.  I then went inside the frame and plug welded the 1/2 inch plate to the frame.  Lastly I welded the perimeter of the 1/2 plate to the frame. 

This has doubled the thickness of the frame at that point.  I trust it, but others may not.  I also did not remove the engine or anything but the strut rod bolts and plate.  By welding outside the frame the strut rod remains the same length.

Hopefully this will help you.  Most Welders should be able to do this in less than a day.  I'm not a pro and had about 6 hours.

Eric Maclean Co-Admin:
Jeri
If your crack is as shown in Carls pictures it is the differential track bar that has caused it this track bar is there to keep the rear axle assembly from moving side to side under the frame .
The track bar and trailing arms on the Magnum chassis are us a spherical ball end on the bar where is connects to the differential and the frame the problem arise when the dust seals on those spherical ball ends deteriorate and allow moisture to get into the ball and rust develops causing the ball end to sieze which in turn causes the frame mount to flex the frame causing the cracking .
At this point a good welder should be able to repair the frame as Carl had done to his .
But at the same time that track bar should be removed and checked to make sure the ball ends are free to turn
There is a post in the coach assist section on how to clean and reseal those spherical ball ends .

Hope this helps
Eric

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