Hi Everyone, new to posting here but I have been using the forum as a resource for a couple of weeks now.
My girlfriend and I are working towards renovating a 1975 Excella 500 from the ground up and we have just finished most of the gutting.
http://www.airforums.com/forums/atta...1&d=1560354303
Now onto the frame. Many of the outriggers have rusted through and need replacement. There is also substantial damage to the main frame pictured below.
http://www.airforums.com/forums/atta...1&d=1560354303
http://www.airforums.com/forums/atta...1&d=1560354303
First, the outriggers, I have a little bit of scrap metal available to me and was thing about fabricating my own replacements. The problem is I dont know much about the strength of steel and its welds. Below are some images of my design for the outriggers I could fabricate. Basically the orange plate would be welded into two 1 1/2" x 1 1/2" x 1/4" steel angles. Then I would weld on two additional 1" x 1" x 3/16" steel angles for additional support and weld surface to the frame. I've found most of my outriggers have rotted out where they were welded to the frame, simply because they a very thin gauge steel at this connection. I think I can achieve the bend by cutting off a length of angle and using a metal bender, or taking a piece of flat bar instead, bending it to the angle and then welding it into the steel angle on the bottom support.
So, any advice? Is this overkill or have I made a mistake in my understanding?
http://www.airforums.com/forums/atta...1&d=1560354303
http://www.airforums.com/forums/atta...1&d=1560354303
http://www.airforums.com/forums/atta...1&d=1560354303
Now the frame repair, as you can see from above, there is a small section that is rough shape, inside the channel there is also a lot of flaked rust. I am hoping two doubler plates will make suffice to reinforce this section. Can anyone advise on what the minimum gauge of this steel should be for this repair? I was initially thinking it should run 1 1/2' in each direction past the damage
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http://www.airforums.com/forums/atta...1&d=1560354303
http://www.airforums.com/forums/atta...1&d=1560354303
Lastly, I wanted to add in some rectangular tubing throughout the frame to add some rigidity. I've watched some youtube videos and it seems a lot of people have been doing this. At the end of the day, I just want to reinforce this frame so that it will be strong enough to support the added weight of some 3/4" millwork panels when we get back to putting it together.
Ok, I think thats enough for now. Sorry for the long first post, im a little out of my depth with this metal work and want to make sure I do it right!
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