Originally Posted by wde3477
No doubt the epoxy is up to the task - worried about getting the required prep necessary for adhesion.
I'm considering filling the frame (or the broken section) so I wouldn't be worried about adhesion.
There are a few other potential problems though.
1. Heat - aluminum trihydrate can be added to resins to help dissipate heat but I think you'd have big problems if you tried to fill a whole member, or even a good size section all at one time. Although, I am in NY and could have the truck prepped and waiting for a 0 degree day...
2. I'm sure there's something I don't know about the way the frame was designed. ie, a friend tells me his grand cherokee's AC has a water run off tube that actually goes into the frame. He never knew that until it got plugged and found water in the interior of the car on hot days...
3. NY state inspection. I have no doubt that a resin filled steel frame is MUCH stronger than the frame was, say...two years ago, and maybe even stronger than when it was new - but I don't know how the decide if it passes 'inspection'.
4. Estimating the internal volume of the frame accurately would be very important - so as to have some confidence that it is filled, but also to have the appropriate amount of materials on hand. So far all I can think of is to park on the steep hill in my back yard, cover all the holes in the frame, fill with water then drain/measure. That's how I determined how much expanding urethane I needed for my boat - but obviously a frame would be a huge pain in the butt compared to the boat...
In the end, I'll probably just list it in craigslist and offer to deliver by uhaul trailer...then spend all that time rust proofing underneath my new (used) truck w/ penetrol lol