top frame metal repair

**multicam** · #1 (**permalink**) 03-12-2008, 05:52 PM

Any body in the group replaced the inner trough of a top frame?

The slightly curved inner U channel that holds the wooden nailing strip??
Mine is rusted out and full of holes, especially at both ends. The rest of the top frame, upper and lower surfaces and the ends are nice and straight and pretty rust free.

I'll post pictures soon.

jburning17 · #2 (**permalink**) 03-12-2008, 06:35 PM

I know that I once read a thread from a guy who ground out all the spot welds on his trough. He made a new one, and spot welded it back in.

I tried the search function for a while, but didn't come up with it.

I had some rust issues on mine as well. I don't think it was a much as what you are describing though. Anyway, I bought some sheet metal to repair it. I used some thin cardboard to cut out a template and then traced it on the metal. Cut the metal out with tin snips. Finally, I brazed the new metal over the old porous area. I only had to do two area, but one was the end area like yours.

Finally, I smoothed down the brazing with a burr and a die grinder, and shipped it off to the powder coating shop. I looks fine and works fine.

I did a similar thing for making a new stapling strip. A friend gave me a thin piece of plywood, maybe 3/16". He held it up to the frame while I traced the arch. About 3/4" strip width worked well for me. Coated it with surfboard resin (you only need about an ounce) to seal it from water. Installed. Looks like it belongs there.

I hope that helps. I'll take a picture of it, if you need me to....

Jon

jburning17 · #3 (**permalink**) 03-13-2008, 07:35 PM

I should have taken some pictures before I sent if off to the powder coaters. You can't see much with that gloss black on there. You can get the idea of the wood strip easy enough.

The point is that you can do it. If you can braze, or know someone who can, then you are golden. You will use $2 is sheet metal, and not much in brazing material either. Just make a template of the bottom shape and cut the metal strips. Braze them in as flush to the bottom as you can.

Ditto with the wood strip.

I hope that this helps out...

Jon