Sterling frame project

Hey everyone. Thought I'd share my latest project. Frame under the sleeper started rotting and decided I'll replace it. Been a long 3 days, but I have new frame bolted to cab mounts. Getting back cross member welded tomorrow and the plates the shocks and air bags sit on welded up. If only I could weld...... any who here's some pictures of the old frame.


Sorry first time uploading pictures. The new frame I'll have pics Monday. Going with white paint. Worst case I decide I don't like it and repaint it. Would any of you attempted this or just have a shop do it? Just curious. All in I'm at approximately 300$ in for all material. Just time consuming.
Actually I am replacing the shocks, airbags, and level valve and air lines so my 300 will go up Monday. Though just for the frame I'm right around 300$. All in all I learned more about the floor plan and know what to do in the future.

 

Only reason the frame rotted away was due to no protective coating on the inside of the tube. By the cab mounts, there was a hole on each flange approximately 3/4" in diameter. Small... but enough to allow the frame to rot away inside out over the life of the truck. I was able to reuse the flanges (tried mocking up my own, but needed a welder in the end and... well... I know what my welding is like) and created a slip to go over the new I-Beam. Powder coated the flanges, primed and painted I-beam flat white, and base plates for air bags and shocks is gloss white. Actually pretty much any part of the frame you can see from the side of the truck I made a gloss white.

Just getting some angle iron welded up today to the rear cross member then bolt the last bit up and hopefully be done with this Monday night. Will have final pictures after all is bolted up.

As to loving my sterling... love does not begin to state my feelings for this truck... lol

 

I am kicking around the idea of buying a mig welder. I tried to weld when I use to turn wrenches and just never grasped the concept of it. I really SHOULD learn it and I agree with scrap metal and practicing. After watching my brother-in-law weld what I needed done and he made it look easy.

I appreciate the tips! I will buy a welder in the next few months, along with a plasma cutter or torches. In regards to the DIY... I really hate others working on the truck, especially when I am more than capable of performing the work. Plus they always manage to get grease on whatever I don't put plastic over... In all honesty, this project isn't as difficult as it seems. Looking back on it, I would have approached it differently and probably saved some time. Buying all my materials at once would have helped as well. I have already started a write up and hope that it will help the next guy/gal that has a Sterling.

By tomorrow night I expect this to be ready to hit the streets for a mini test to make sure nothing catastrophic occurs. I'll have final pictures up some time this coming week.

 

Update.

Have to run air line to air bags on chassis (it was leaking very slowly). Have to bolt pass side plate (where shock and air bag connect) to rear cross member. Then I'll be done. Will have many pictures!

 

Job is finally done. Test drove truck on 3 trips. Bobtails 100x better, empty w/ trailer is smooth and fully loaded it's night and day difference! Up next will be new shocks and air bags.
Really pleased with how this ended up. Never thought I'd ever be doing this though. I plan to do a write up, and hopefully others who attempt on their truck will have an easier time.

I'd do this again if I had to....