Use two pieces if necessary and set the same 1/8” root opening, the size of the runon tabs is not important, only to match the ¼” frame thickness.
5) Once run-on tab is tacked, weld the top side (inside) of the I-beam frame. Begin on
the run-on tab and end where the hole is located (reference figure 5).
6) Next, back gouge from the bottom side to sound metal using appropriate means
(grind or carbon arc.) A full penetration weld is required here so be sure to verify
gouge is deep enough.
7) Once back gouge is complete, finish the overhead weld (reference figure 6).
8) When welding is complete here, cut off run-on tab and grind edges smooth. Also
grind the top and bottom sides of the repaired weld face flat if the reinforcement is
beyond 1/8” high or the toe angles are not optimal. (If weld looks good, you will still
have to grind the top side (inside) weld because a plate sits there) (Reference figure
7 & 8).
9) Retest finished weld by dye penetrant or magnetic particle to verify no cracks
occurred during the repair process and weld repair is acceptable.

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Welding of stiffener plate(s):
1) Next, weld in the supplied or cut stiffener plates to reinforce the area.
2) Place stiffener plate in between the I-beam frame flanges, pushing in towards the
web for a snug fit, and butt against existing fender front gusset (reference figure 12).
The face of any weld repair will need to be ground flat here if not already done. Any
areas the stiffener plate touches will also need to have the paint ground off if not
already done. Tack the plate in place.
3) Begin by welding the top and bottom sides of the plate to the beam flanges with a .2”
fillet. Be sure these fillet welds tie-in properly to any existing weld. Grind a transition
tie-in gouge into the existing butt weld if necessary to make a clean tie-in to the new
fillet welds. Also, at the termination of the horizontal welds - extend weld bead
termination as a run-out – 1” straight and 1” diagonal as shown in figure 13.
4) Then weld the vertical joint with a .2” fillet (reference figure 13).
5) Repeat welding of the plate and subsequent steps for opposite side of trailer frame as
well
Final work:
1) Inspect all welds in accordance with the weld quality acceptance criteria listed on
page 12. Repair any defective welds and reinspect. If defects (no go) are found,
remove and repair them using one of the weld processes listed in this document.
2) Remove any temporary tacks that are outside weld joints.
3) Grind any hard notches or unacceptable weld profiles down. Pay particular attention
to having a smooth leading etch on the run-out weld beads from the stiffener plates.
4) Reinspect general area to be sure no cracks formed during the repair process.
5) Paint area as required once weld has cooled.
Welding Parameters:
Base Metal Preparation:
1) Before tacking or welding, the base metal within 3 inches [76mm] of the weld joint
in all directions must be at or above the preheat temperatures listed below. During
welding, the base metal temperature must be maintained above the preheat
temperature and below the maximum interpass temperatures listed below:
2) Minimum preheat: 50ᵒF [10ᵒC]
3) Maximum interpass temperature: 500ᵒF [260ᵒC]
Work Lead Connection (Grounding):
1) Welding or cutting work leads (commonly referred to as a grounds or ground
clamps) should be attached directly to the weldment being repaired/modified and
as close to the point of welding or cutting as practicable. Additionally, it must be
firmly connected to bare metal (paint removal is usually necessary). In no case
shall the ground path be allowed to pass through bearings, electronics, bolted
connections, or other sensitive components or connections.

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Gas Metal Arc Welding [GMAW/MIG/MAG]:
1) Environment: This process shall only be used when welding can be performed in
a shop environment and the weld joints can be positioned in the flat or horizontal
positions. If vertical or overhead welding is required, FCAW or SMAW are
recommended.
2) Electrode: AWS classification ER70S-3 or ER70S-6 [ER48-S6] (e.g. Lincoln L50
or L56)
3) Size: 0.045" [1.2 mm]
4) Wire Feed Speed: Minimum 350 IPM [9 MPM] - Maximum 520 IPM [13 MPM]
(optimum 450 IPM [11.5 MPM])
5) Voltage: Minimum 26 volts - Maximum 30 volts (optimum 27.5 volts)
6) Amperage: Amperage is a function of wire feed speed, but should read in the
range of 250-370
7) Electrode Stickout: ½ " – ¾ " [12 mm – 20 mm]
8) Shielding Gas: 95% Argon - 5% Oxygen or 90% Argon - 10% CO2 at 40 cfh [1.1
cmh]
9) Position: All welding should be in the flat or horizontal position. Vertical welding
shall be uphill. No downhill welding is permissible.
Flux Core Arc Welding [FCAW]:
1) Environment: This process should only be used when welding can be performed
in shop environment for all welding positions. Protect the area from wind and
moisture. If field welding is required, SMAW is recommended.
2) Electrode: AWS classification E71T-1M [E491T-1M] (e.g. Lincoln Ultracore
71A85)
3) Size: 0.052" [1.3 mm] or 1/16” [1.6mm]
4) Wire Feed Speed: Minimum 200 IPM [5 MPM] - Maximum 500 IPM [13 MPM]
5) Voltage: Minimum 23 volts - Maximum 30 volts
6) Amperage: Amperage is a function of wire feed speed, but should read in the
range of 220-370
7) Electrode Stickout: ¾ " – 1 " [20 mm – 25 mm]
8) Shielding Gas: See electrode manufacturer recommendation (usually 75Ar/25CO2
or 100 CO2@ 40 cfh [1.1 cmh])
9) Position: Flat, horizontal, vertical and overhead positions are permissible. Vertical
welding shall be uphill. No downhill welding is permissible.

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Shielded Metal Arc Welding [SMAW/MMA]:
Environment: This process may be used in either a shop environment or field
environment for welding positions. Protect the area from wind and moisture.
Electrode: AWS classification E7018 [E4918] or equivalent
Size: 1/8" [3.2 mm] or 5/32” [4.0 mm]
Polarity: Direct Current Electrode Positive
Amperage: 110-135 amps for 1/8” [3.2mm] and 125-200 amps for 5/32” [4.0mm]
Position: Flat, horizontal, vertical and overhead positions are permissible. Vertical
welding shall be uphill. No downhill welding is permissible.
Electrode Condition:
•
•
•

•
•

All electrodes shall conform to AWS specification A5.1 and should be
purchased in hermetically sealed containers or should be baked by the user in
an oven one hour between 500°F [260°C] and 800°F [430°C] prior to use.
Immediately after opening the hermetically sealed container, electrodes
should be stored in ovens held at a temperature of at least 250°F [120°C].
After hermetically sealed containers are opened or after electrodes are
removed from baking or storage ovens, the electrode exposure to the
atmosphere should not exceed four hours. If electrodes have been exposed to
the atmosphere for more than four hours, they shall be rebaked in an oven for
one hour between 500°F and 800°F [260°C and 430°C].
Electrodes should be rebaked no more than one time.
Electrodes that have been wet shall not be used.

Weld Quality Acceptance Criteria:
•

VMV000088 Rev. 1

All welding shall be in accordance with the figure below. Any welds that do not
conform (no go) must be repaired to bring them back into compliance (go). It
is the responsibility of the company performing the repair to inspect the welds
and ensure that they meet these quality requirements.

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VMV000088 Rev. 1

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Weld Procedure Figures 1 through 13:
Figure 1: Complete trailer frame, left side fender made transparent, work area emphasized.

Figure 2:

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Figure 3:

Figure 4:

Figure 5:

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Figure 6:

Figure 7:

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Figure 8:

Figure 9:

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Figure 10:

Figure 11:

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Figure 12:

Figure 13:

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UNIT OWNER COPY:
Insert in parts manual
for future reference.

1

Kit 1

Kit 2

1

Kit 3

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Kit 1 parts list –
VMV020088
REF.
NO.

PART NO.

DESCRIPTION

1

F250-4955

Stiffener, 800 Frame

VMV020088
QTY.

Remarks

2

Kit includes all items in Kit 1 parts list.

Kit 2 parts list –
VMV030088
REF.
NO.

PART NO.

DESCRIPTION

1

F250-4955

Stiffener, 800 Frame

VMV030088
QTY.

Remarks

2

Kit includes all items in Kit 2 parts list.

Kit 3 parts list –
VMV040088
REF.
NO.

PART NO.

DESCRIPTION

VMV040088
QTY.

1

135017633

Wldmt, LP800 Hvy Int. SHT w/200 Gal. Water
Tank

Remarks

1

Kit includes all items in Kit 3 parts list.

VMV000088 Rev. 1

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