Cast Aluminum Door Frame Repair

[DaddyBob]

Had a high speed blowout that caused the inner cast aluminum door frame to break in three places. This was 13 years ago. Have searched off and on for a replacement/repair solution since then - to no avail.

Now considering a combination of epoxy/fiberglass/acrylic to repair the frame or at least improve structural integrity. The door currently flexes, doesn't seal entirely, and must be secured with duct tape when on the road.

Anyone have a similar issue and/or solution?

[Bubba L]

You could give Luke a call in Ft.Collins. Luke’s Maintenance and Repair. He works on Airstreams. We have a 66 Safari and the aluminum framed screen door is flimsy. Can you check around and have someone re-weld the corners? I guess you could get a small sheet of 14ga aluminum and cut some 3/4” corners and screw them to the frame. I don’t know how bad it is so hard to suggest. Good luck

[Ndcctrucks]

Take the frame and pieces out and have a welding shop TIG weld them back together.

-Ken

[Aerowood]

My 71 Globetrotter cast door frame was cracked in multiple places. At some point it it's life prior to my ownership it had been involved in some sort of accident. The door skins and skin aft of the door had been replaced with a soft alloy. The door frame it self had several steel doublers bolted to the inside. It was a real mess to say the least. I removed the door and all the skin to evaluate and found more cracks. If I remember correctly it had 7 cracks with two places that the frame was completely severed. Both of those had the steel doublers and were on both sides of the hinge location. A co-worker of mine in the aviation business was a certified welder. We were able to get the frame reformed and he was able to weld every crack. I then reworked the frame at the latch area and replaced the KT lock with a much better and cheaper latch. I reskinned both the inside and outside and it has been trouble free for many years now.
There are several pictures in my 71 Globetrotter Full Monte thread.

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[Steamfitter]

Looking for a bit of confirmation that this busted piece is actually Cast Aluminum and can be TIG welded? Any other feedback would be greatly appreciated.

[Aerowood]

Yes it can be Tig welded. My welder friend said the cast aluminum was dirty. I would suggest that you make a wooden form to help hold the shape while welding.

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[Steamfitter]

Originally Posted by Aerowood

Yes it can be Tig welded. My welder friend said the cast aluminum was dirty. I would suggest that you make a wooden form to help hold the shape while welding.

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Thank you for the prompt reply.

[Aerowood]

I also re-skinned both the inside and outside. The welding was done with no skin on the door so that he could weld completely around the breaks in my frame. I do have pictures somewhere in my "71 Globetrotter Full Monte" thread.

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[InvertdEagle]

Aluminum can be Tig welded quite successfully. If the welder knows his stuff, it’s not a technically difficult repair. Hardest thing here is making up a jig to hold everything in the right position during the weld.

Alternatively, maybe finding a donor or wrecked Airstream in a boneyard somewhere that you could salvage from.