1999 - Can crack be fixed without welding?

[jr1under]

My 1999 developed a stress crack in the area where the driver side liftgate strut connects to the frame. Over the last year+, I've contacted almost every shop in the area that mentions welding and none are interested in the job.

So, how to get the liftgate functional again? Could I fasten a plate over the bad area with something like jack nuts? That may be a terrible idea, I don't know, and I'd appreciate hearing from anyone who has a better one.

 

[JamaicaJoe]

You would want to drill the ends of the cracks to stop the propagation of the crack. Can you get behind the crack or is it in the blind? I can't imagine at least one good welding shop that cant butt weld the crack. Maybe a larger washer under the bracket could spread the stress.

 

[jr1under]

Plenty of shops in the area are capable of handling this but none of them wanted to and I don't really fault them. Mine is a small, unusual job and they're booked solid with much more profitable work.

Can't get behind the crack. As you said, spreading the stress is the key so I trimmed a piece of thin steel plate to fit over the area where the crack is. Drilled a hole for the existing connector and fastened the new plate to the original with 3/4" #10 self-drilling bolts. It's solid now but no predictions for how long that remains true.

 

[jr1under]

It's been well over a year with no issues since I did this so here's a picture of the end result. About as pretty and artistic as I am but 100% functional.