Frame rail repair

The picture doesn't look as bad as I was imagining -- I don't think it is OOS if it isn't cracked or sagging & the only thing remotely structural in the vicinity is a shock absorber.

Unfortunately, a cursory web search shows Volvo frames are heat-treated, which means a thorough repair job is beyond the scope of your local all purpose welder.

Given your plans to replace the truck in the next 2 years, I'd be inclined to media blast it, make sure it isn't any worse than it looks, and repaint it. Then keep a close eye on it during PTI's, but continue to run it as is. Welding a patch w/o proper heat treating would likely be worse than leaving it alone.

This is all I found (49 cfr 399):


9. Frame.

a. Frame Members.

(1) Any cracked, broken, loose, or sagging frame member.

(2) Any loose or missing fasteners including fasteners attaching functional component such as engine, transmission, steering gear, suspension, body parts, and fifth wheel.

 

Need to clean and seal up from spreading. Was that from salty road spay over the years? Rust Mort is a rust sealer but only a band aid till getting media blaster and a good sealer.

 

Is that a box?? Frame or the c shaped frame?

 

Many years experience in the fertilizer business here. Stretched, shortened, patched, double framed, made two trucks one etc. Still consider myself junior league. That would highly concern me staying in the county and would have to be reinforced, would not send it over the road. Maybe not OOS but 15 days to fix your stuff?
Do not weld 2nd rails to the first, bolts only. Then you want a x-member at the bad spot & or joint but you have an engine in the way. Both sides the same is a good idea. If you can not find a piece of frame from another truck that fits tight over yours a good fab shop can make one.
The last frame rail I priced was for an 87 AutoCar and it was $5000.00, in the 90's, Comes with all the holes drilled from the front bumper to the back of the cab. Not beating on your truck but what is an 01 Volvo White worth?
If it were mine I would check the rest of the frame and I hope it is OK. Bolt a c channel section over that area. That will buy some time to keep running and go shopping. Hope it is not a cream puff with a lot of money in it.
You should be able to get that done without spending a fortune.

 

The problem is that your solutions are not a real fix, there isn't short of frame replacement to fix it right, and at the cost of it being done right, opposed to cheap, it is better to replace the truck.

The other part is this is rust through at a key point as described by the OP, which is near the engine and shock mount, places where the repairs are a PIA and have to be done right. The weight of the engine/transmission is one problem, it isn't just weight but also the torque the engine produces that can rip up a frame repair.

If he is caught driving that, and gets a level one, he is OOS - no officer will let that go. The officer can cite a few regulations, not just for the frame.

 

Time to change trucks.Unless you want to Keep it For the next 10y.

 

May be like the do restoring cars. Make one good one out of two. Lots of good info on old truck sites on frame repair and replace but usually behind cab.

 

Sir... your truck has just been determined to have cancer! and it is terminal. with treatment it may last a little longer, but the end in near. please make plans for burial.

 

sub'd. I'm going through similair struggles.