to weld or not to weld

I know everyone has their opinions on this and it's been gone over before, but what I would like is to hear from those that have welded to the unibody, esp in the front steering box area. How many miles/wheeling trips are on since then? How is it holding up? What other bracing/reinforcing was done at the time? Pics would be great also.

What I have done is cut the lower rad support out, fab up a "box" to mount a winch in and tuck it under the radiator. I also added a stinger to it. I ran the plate past the steering box mounts so the box will be supported by 1/4" plate on the outside. I also used the 2 front bolts where the oem bumper would attach. The pass side is the same way, basically 5 bolts holding it on. I am going to weld it along the top right under the grille on both sides. I am running hydro assist so there won't be alot of stress on the steering box area. I also have an exo brace that attaches to the side of the box near the steering box area on both side, so it is in essence, tied in to the cage.

I was originally planning on welding it but every grain in my body says that is a bad idea. My opinion on the matter is that it weakens the unibody more than in would strengthen it.

Anyway, what have those who have welded come up with?

Thanks.

Hamy.

Welding should be fine as long as it's hot enough to get deep enough into the metal on the unibody and the item being welded on. Arc welding is best IMHO.
If done right, it'll be strong and probably stonger than the rest of the unibody.

Make sure you don't have any rust/rot in the area you are welding. It'd be like welding to a piece of cardboard!

Many folks have plated the steering box area to add beef and to repair cracking. Not sure what the big deal is about welding on the unibody, the factory did it to assemble the rig, right?
ARC welding will definitely require more skill to prevent over-penetration and burn through, MIG is much easier to fine tune when mating two different thicknesses of metal on your rig. Remember to remove all paint, undercoat and zinc coating with an abrasive disc or the like in the area you will be laying down a bead, for best results

I see absolutly no issues to welding on a unibody, wether its an XJ or a
Triumph. Proper prep, heat and someone qualified as a welder will face no
issues performing the task.

Welding to the unibody causes death wobble.

When I did my front, I used 1/4" plates on the outside frame rails, Plasma cut the steering box bolt holes and a couple for bung welding, then welded all the way around it skipping around in an even pattern. This 1/4" plate goes from behind the drivers side spring, all the way to the bumper where it is reinforced with 4" x1.5" channel that goes back to just before the spring. The 1/4" with the 4" channel combine to make a boxed frame forward of the springs...I don't think I'll have a problem.

Inside, I plasmacut a 1/4" plate to be as large as possable to distribute the load better. Made some spacers outa 1" stock and welded them to the plate. I cut bung holes for welding, drilled it from the outside, and bolted the box on with new grade 8.

Then I wanted to tie the steering box to the other frame rail.... I got a sturdy looking heavy duty muffler clamp that fit PERFECTLY around the output of the steering box. I welded that to a piece of 2"x3/8" that I bent and twisted to mate to the passenger side frame. This was welded in after everything else tight and finished being welded. Then I put a couple good tacks on the steering output to muffler clamp. - heh

Across the front of the frame I also layed a 6"x 1/4" plate across and welded it with 2" and 3" stitch welds

First trip was to Moab in 03' for the 20th of the XJ. Since then I have had all four tires in the air more times then I can remember. I've hit so hard on my front end at wide open throttle in 3rd gear low, that I sheared 3 teeth off my dana 44 ring gear! -that was nuts but atleast I didn't roll!

I rammed a ford escort and sent its radiator into its valvecover! :firedevil then I drove onto the hood with 1 tire and took a pic.
And if that wasn't enough fun for me..... I rammed a junk F150 goin about 25-30MPH while we were on our way to the junkyard with it! hah I smashed the box right off the frame it was so rusted! hahaha when we got it to the junkyard, I gave it a final T-bone goodbye, it blew out all the windows on the passengerside and the back window.

Even after 2 years, serious abuse on the trails, and ramming fords, I am happy to say that there is no signs of cracking or bending or ANYTHING. It just works sweet.

I wouldn't worry too much, just be careful, don't burn through! Take your time and you will be happy!

They told me not to build my own longarm brackets because I had no experiance welding unibodys... heh well, I had longarm on my XJ before the XJ longarm kits where on the market. Not one of my welds shows ANY sign of fatige.

I have NEVER had death wobble with my XJ......

Buy a steering stablizer....

Or if you did warp the frame welding it........ LEARN HOW TO WELD!!!

sorry...

Ha Haa.......Urban Mythes & 110 mig welders from Harbor Frieght cause
DEATH WOBBLE!!!!

Man, I wasn't even fishing and that one jumped right in the boat.