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Old 12-10-2019, 11:21 PM   #1
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1993 Safari Continental 37' cracked frame from a botched Koni shock installation

What a nightmare.

Did some front end work recently, noticed that both sides of my frame are cracked at the shock mounts connecting to the frame.

Who in their right mind uses a bolt without a washer or a back plate?!
Especially on a load bearing component.

Pioneer metal works in Washington state did this.

This is what they had to say:
"We put our product on in the original shock bracket position where the manufacturer had put the original shock bracket. We did not drill any additional holes that might weaken the frame. What we added did not add any additional stress to the frame. - Pioneer metal works

Clearly, they have relocated the shocks.

Thanks for reading, ill keep you updated.
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Old 12-11-2019, 05:12 AM   #2
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I’m confused, your 2 pictures don’t match. Where is the line through the frame...don’t see it in the first picture??? Put a backing plate bigger than the front and forget about it. Cracks in the side of the frame are not going to hurt its strength.
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Old 12-11-2019, 05:31 AM   #3
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The cracks I see in the second pic look old. How long ago was this done?

As previous poster said, a large backing plate could be an easy fix.
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Old 12-11-2019, 05:44 AM   #4
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Looks like very old work, but shocks that are too long and bottom out, may have contributed to the stress and cracks.

You will need to find the specs of the shocks collapsed lenght and then take some measurements of the axle travel to the bump stops.
The bump stops should be contacting before the shocks close completely.
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Old 12-11-2019, 09:06 AM   #5
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Hi Psam
Welcome to the forum & I'm sorry for your trouble. FWIW I used the Tiger Trak products on my Safari, including radius rods & Tiger Trak bar & was very happy. I did not utilize them for install I did that at home myself.
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Old 12-11-2019, 01:27 PM   #6
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I did not see a spot where there was an old back plate or large washers ,if not included they didn't add one. I do a lot of industrial work not a lot of wahers are used on large equipment if so they were usually added by mechanics after the build. If alot shear stress was induced to bolts ,washers would not have helped alot. Is there puckering or bending where bolts were trying to pull bolts through the frame.
I would do what was suggested inspecting the shock throw. I hope all works out.
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Old 12-11-2019, 11:14 PM   #7
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This was a modification that clearly required reenforcement.

The shock installation was done nearly 10 years ago.
I am going to fishplate the outside, and slide in a new piece of C frame on the inside of the RV frame.

Pioneer metal works changed the text on their website after i contacted them.
They no longer say "we stand behind our service 100%"

They lied about relocating the shocks from the factory position.

I was just about to spend the winter in Arizona. At least i didnt find out on the highway.
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Old 12-12-2019, 02:54 PM   #8
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Shocks

Looks to me that the shock bracket was relocated due to the gusset or bracket under the original holes.
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Old 12-13-2019, 08:07 AM   #9
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Quote:
Originally Posted by twinboat View Post
Looks like very old work, but shocks that are too long and bottom out, may have contributed to the stress and cracks.

You will need to find the specs of the shocks collapsed lenght and then take some measurements of the axle travel to the bump stops.
The bump stops should be contacting before the shocks close completely.

Yup.
That needs to be resolved. How is the ride now? time for shocks again?
Hard to tell from the pic but the top mount looks higher on the frame rail than the original position. So that should allow the bump stops to hit first (like they are supposed to). But that depends on the new angle of the shock.
Anyway, yes gusset the frame. but the mounts / shock lengths need to be re-evaluated to ensure the mount isn't getting undue stress.
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Old 12-13-2019, 12:57 PM   #10
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Whoa frame rail's do not fracture like that...would be my first thought. Bend...tear...but not fracture, if i were you i would take your rv to a truck frame repair straightening body shop type of business. See what there opinion would be from a repair stand point...Only high heat can cause steel to become that fragile....With that being said...life is full of surprise's this will be interesting..

https://weldingweb.com/showthread.ph...uck-frame-rail
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