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Frame Horn Question

Discussion in 'Early CJ5 and CJ6 Tech' started by givemethewillys, Feb 12, 2021.

?

Repair the section, or replace the entire frame horns?

  1. Splice in a repair piece

    33.3%
  2. Cut off the entire frame horn and replace

    66.7%
  1. Feb 12, 2021
    givemethewillys

    givemethewillys Been here since sparky ran it. 2022 Sponsor

    New Kent, VA
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    Jun 21, 2005
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    1,998
    Hey guys, I have a question about frame horns. So in my '57 project, i sourced a frame from a '70 cut that is in general much better shape than my original frame.

    I was swapping out the hanger bushings in preparation of installing my dana 30, when I noticed this on the passenger side:

    Screenshot_20210212-125515_Gallery.jpg

    The shaft that holds the bushing in is half rotted away! At the same time, the bottom span of the frame horn has some damage in front of the hanger mount location.

    Should I replace the entire frame horn? Or would it be better to splice in a section of the c-channel that holds the hanger?

    On the drivers side, the frame horn is bent upwards about 1", so I have the same question: should I replace the entire horn, or somehow bend it downwards?

    Sidenote: the '57 frame that I'm replacing has reinforced frame horns, with freshly welded in hangers.
     
  2. Feb 12, 2021
    timgr

    timgr We stand on the shoulders of giants. 2022 Sponsor

    Medford Mass USA
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  3. Feb 12, 2021
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    I’ll always answer this question the same way. Replace with tubing. The front horns are the worst part of the design of the early CJs. They were under-built to begin with, then we go and put bigger tires on, add a winch, throw the steering box out there, then drive it over rocks.... the original steel is a ticking time bomb. Tubing replacement is just as much work, if not less, than repairing and boxing the original horns, and the added strength is huge.
     
    givemethewillys and Fireball like this.
  4. Feb 12, 2021
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
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    It's a very high stress are and should probably replaced. They like to crack even on non-rusty frames.

    Here's mine prior to welding up the cracks:
    [​IMG]

    If you're not going for originality, 2x4 tubing makes for good frame horns. Dne did a nice job with hers: Yep, Bought A '68 Cj5(project)
     
    ITLKSEZ likes this.
  5. Feb 12, 2021
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
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    Hah, Ryan beat me to it!
     
    ITLKSEZ likes this.
  6. Feb 12, 2021
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    givemethewillys and Fireball like this.
  7. Feb 12, 2021
    givemethewillys

    givemethewillys Been here since sparky ran it. 2022 Sponsor

    New Kent, VA
    Joined:
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    To give a bit more context to the conversation, here's a better picture of the passenger side frame horn:

    Screenshot_20210212-155103_Gallery.jpg

    And the drivers side (note the crack, and it's tilted upwards 1")
    Screenshot_20210212-155342_Gallery.jpg
     
  8. Feb 12, 2021
    givemethewillys

    givemethewillys Been here since sparky ran it. 2022 Sponsor

    New Kent, VA
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    I really liked what you did with yours @ITLKSEZ . Dne's looks good too. Looks like so far the 2x4 replacement is in the lead!
     
  9. Feb 12, 2021
    Dne007

    Dne007 Well-Known Member 2024 Sponsor 2023 Sponsor

    Cypress, Tx
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    This was one of the most nerve racking things I've had to repair, I did a jam up job,but I was worried about it until the end! Now it looks fantastic and, "Did I do that repair?" lol

    In the beginning, I knew there was something wrong with this picture!
    [​IMG]

    A lot of work later, it came out like this, re-enforced and all pretty! And ready for my power steering gear to boot!
    [​IMG]

    I'll help you anyway I can!! ;)
    dne'
     
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  10. Feb 12, 2021
    givemethewillys

    givemethewillys Been here since sparky ran it. 2022 Sponsor

    New Kent, VA
    Joined:
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    I have two of those that I just welded onto my '57 frame. I was thinking about cutting half the span of the c-channel and welding it in, and then boxing the inside of the frame horn, if I went that direction.
     
    Dne007 likes this.
  11. Feb 12, 2021
    Mr Vaughan

    Mr Vaughan

    i see some seriously thick steel boxing...


    looks familiar
     
    Dne007 likes this.
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