Repairing The Stress Cracks In KITT's Frame

Troy came over tonight to weld the stress cracks in the frame where the steering gear box mounts. He was surprised we had missed these cracks before, too. There were a few more than he was expecting, but nothing as bad as what I have seen online. 

We started by drilling a stop hole at the end of each crack to create a stress relief point and prevent if from spreading any further. Then we used the rotary tool to grind grooves/channels over each crack. This will allow the weld to spread out and cover the area.

Here you can see the channels that follow along each crack. You can also see the four stop holes I drilled.

I threw this picture in here for no other reason than I thought it was really cool looking. :)

Here is a video of Troy welding over the cracks in the frame caused by the stress put on it by the steering gear box. You may want your shades. ;) 

[cue the music]

And I wear my sunglasses at night
So I can, So I can
See the light that's right before my eyes.

Here is the finished repair. I will grind the welds down tomorrow and start prepping the area for paint.