W126 frame failure
 

Had my front end up to inspect things before winter hits. I think most are aware of the support braces that can fail on a W126.

http://www.peachparts.com/shopforum/body-repair-restoration/293938-cracked-frame-w126-owner-alert.html

Just a heads up for the new guys. Today I found that while the supports are still sound, my frame has developed a nasty hole and or crack about 3 inches behind the support. This was not visible this summer.

I will be removing as much of the undercoating as I can and see how bad it really is. Luckily I have a friend that can repair the frame. Scary stuff!

Got the car into today at the local Studebaker shop. Find out the "frame" is not really a frame at all. Instead really just a design to stiffen the body up. Its a thinner metal and 3 sided. A true frame would not really look like this.

Anyway, cleaned it all up and did some welding of the hole. Turned out pretty well. I will get a few pics up when I can. Overall I feel safer driving.

That's the time! If metal around your weld is not solid, you can fabricate a sheet metal patch that will tightly go over the boxed area far enough to reach solid metal and MIG(or whatever you have for welding sheet metal) that in place.

Take some pics too! If you can.

I did take pic and a plate was indeed welded in place after removing all the rust and bad metal. I will get pics up in a bit.

Pics of the work. When grinding I did find a lot of orange "filler". Something they spread on the joints, etc. Above my upper control arm is visible and uncoated. Clearly something that is brushed on.

At the end it was ground and coated well. New undercoating always looks so nice! Someday I will do the entire car after some spot grinding, etc.

If this is on the left side (which it appears to be) check your battery tray for acid leakage. This appears to be a weak point in the design of the W-126's. You'll probably find the trail of corrosion leading down the firewall.

Also check your wiper hose check valve. Those are prone to cracking and then all the wiper fluid just leaks down into the battery tray area.

They battery tray is toast. No leaks from the tank or hoses for washer fluid. But both are new. Tank replaced by PO and battery by me, although the OEM battery before did not appear to leak.

So at one time, I suspect maybe some issues. I will probably pull the battery soon anyway, time to de-leaf the car.