Is the 150 showing any signs of cracked inner guards

[krypto]

One technique a sheet metal worker showed me on my old Hilux which had a crack on the inner guard, was he drilled a hole, 1/4 " at the end of the crack, and then welded the rest of the crack up. Once it cooled, painted it all in rust proof.

He said if we just simply weld it all, it will continue to crack over time. He was right in my instance. Never cracked again.

Not saying it will work in ever case, but the crack on the lux was about 100mm long, and I could get my finger nail in it.

Drilling a hole reduces the stress concentration. Have to be careful welding as that can introduce new stress.

[outback7]

Hey Wooley, I talked to Roo about that he said no.....different shape guard. Roo is trying to source one for the 150.

[Hutch]

Makes sense same as a crack in the windscreen we use to drill at the end of the crack and then fill with resin.


Hutch- 2012 Prado 150, some TJM Kit.

[AJ120]

One technique a sheet metal worker showed me on my old Hilux which had a crack on the inner guard, was he drilled a hole, 1/4 " at the end of the crack, and then welded the rest of the crack up. Once it cooled, painted it all in rust proof.

He said if we just simply weld it all, it will continue to crack over time. He was right in my instance. Never cracked again.

Not saying it will work in ever case, but the crack on the lux was about 100mm long, and I could get my finger nail in it.

That is not only true for sheet metal, we do that with cracks in earthmoving machinery which may be upto 20mm thick steel in some instances. Definately the correct way to repair it.

Cheers Andrew

[Geoffury]

One technique a sheet metal worker showed me on my old Hilux which had a crack on the inner guard, was he drilled a hole, 1/4 " at the end of the crack, and then welded the rest of the crack up. Once it cooled, painted it all in rust proof.

He said if we just simply weld it all, it will continue to crack over time. He was right in my instance. Never cracked again.

Not saying it will work in ever case, but the crack on the lux was about 100mm long, and I could get my finger nail in it.

[smakb]

If it aint broke don't fix it!

Cheers Andrew

And for those who have a broken one? If welding the crack does not fix it and it keeps coming back?

I don't mind if it breaks if there is a fix, but for those who have had it crack, what's the solution?


Steve.

[AJ120]

So what's the answer?


Steve.

If it aint broke don't fix it!

Cheers Andrew

[smakb]

If you're going to reinforce the guards you really need to be careful that you don't create new stress points for cracking.

So what's the answer?


Steve.

[krypto]

If you're going to reinforce the guards you really need to be careful that you don't create new stress points for cracking.

[AJ120]

Just a little story you might like to hear before you go beefing up the gaurds.

Many years a go when I worked as a welder in a car factory; one of the workers ordered a new car and he got the build number pre production and went along the production line; following his car and getting all the welders to put lots of extra welds on everything in order to make it much stronger.

Long story short, the car was a pig to drive and started to rattle and crack within a couple of years, and this was a town car not a 4wd. Cars are meant to flex a bit and making them stronger isn't nescessarily the best answer, you might just create another problem, or shift the stresses to another point due to a lack of flex.

Something to consider before spending money fixing a problem that hasn't occured yet!

Cheers Andrew

[wooley]

I agree Hutch......I think It will be an isolated issue with the 150's judging on what I have heard from Toyota and others. I have just done 6500 k's on rough corrugations, rocky steep tracks, sand hills, water crossings. No cracks so far. I am going to get a quote from a panel beater on getting some guard reinforcing plates made like a French company did for the 120. Just for some insurance. Maybe Roo could post the photo's of the one for the 120. Did I read that one member paid $800 for the repair on his? I think prevention is better than cure hey?

are you sure the 120 ones wont fit?

[outback7]

I think these r isolated incidents based on set up and the type of travel undertaken, I don't think any car is perfect and given certain types of travel/ treatment any car will have it's faults, Prado's just happen to be inner guards which in reality don't seem to be that expensive to fix.

I agree Hutch......I think It will be an isolated issue with the 150's judging on what I have heard from Toyota and others. I have just done 6500 k's on rough corrugations, rocky steep tracks, sand hills, water crossings. No cracks so far. I am going to get a quote from a panel beater on getting some guard reinforcing plates made like a French company did for the 120. Just for some insurance. Maybe Roo could post the photo's of the one for the 120. Did I read that one member paid $800 for the repair on his? I think prevention is better than cure hey?

[krypto]

All the metal on the front of the car is press formed.

I have had a fair bit of experience with metal forming. In theory every sheet turns out the same when you press it. In practice there may be minor variations due to differences in material structures, press lubrication, etc. So not every pressing is identical, this is okay until you introduce high loads or a stress raiser such as a sharp corner or hole.

This is why I suggested measuring the thickness of the cracked metal and looking for stress raisers in an earlier post.

Bottom line if you have some slightly weaker metal and then add all the extra weight on the front you may get cracks.

[Hutch]

I think these r isolated incidents based on set up and the type of travel undertaken, I don't think any car is perfect and given certain types of travel/ treatment any car will have it's faults, Prado's just happen to be inner guards which in reality don't seem to be that expensive to fix.

I wonder if the thickness of the sheet metal is the same on the body as well as the inner guard and wheel arch? The problem with the inner guard is that it is pressed and where this happens becomes a stress concentrator. Also, this area is where the material thins to form the shape. Coupled that with micro-scopic cracks in the material at that point and you have the alignment of the planets ....