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Car Forum / BMW Cars / July 2007

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88 535i rough ride

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michaelharvey@sympatico.ca - 12 Jul 2007 17:37 GMT
Hi, my mechanic has repaired a broken steering box bracket by welding
it.
This has been done twice and now it is breaking again. What could be
causing
the repeated breaking?

By the way, the car drives so much smoother with the steering box able
to
move around. I think the box is moving even with the bracket not
broken but
sticking so the alignment is off. Then with the bracket broken I don't
think
it is sticking any more, hence the smooth ride. So what else could be
broken, maybe the frame it bolts onto? Does this make any sense?
steve-caner@clara.co.uk - 12 Jul 2007 21:50 GMT
>Hi, my mechanic has repaired a broken steering box bracket by welding
>it.
[quoted text clipped - 10 lines]
>it is sticking any more, hence the smooth ride. So what else could be
>broken, maybe the frame it bolts onto? Does this make any sense?

Sounds as if the chassis is out of line or the vehicle has been totaled at one
time or been in a front end fender bender and not fix correctly.
michaelharvey@sympatico.ca - 12 Jul 2007 22:28 GMT
On 12 Jul, 16:50, steve-ca...@clara.co.uk wrote:
> >Hi, my mechanic has repaired a broken steering box bracket by welding
> >it.
[quoted text clipped - 13 lines]
> Sounds as if the chassis is out of line or the vehicle has been totaled at one
> time or been in a front end fender bender and not fix correctly.

That's correct it has been in a front end collision and some of the
frame was welded before I bought the car. I presume the frame is not
rigid anymore causing stress on the bracket, right? That sounds like a
difficult frame repair, considering the car has a 3 or 4 more years of
life.

If that is correct then I think a loose steering box is able to float
to compensate for frame movement, but that good effect will end up
with another broken bracket. Unfortunately for my mechanic he
guarantees his work so he has to keep repairing the bracket, not a
happy situation for him. What would you advise him to do? Is it
possible to reinforce the frame for a reasonable effort?
steve-caner@clara.co.uk - 13 Jul 2007 14:10 GMT
>On 12 Jul, 16:50, steve-ca...@clara.co.uk wrote:
>> >Hi, my mechanic has repaired a broken steering box bracket by welding
[quoted text clipped - 20 lines]
>difficult frame repair, considering the car has a 3 or 4 more years of
>life.

The car has NO MORE LIFE it is a TOTALED WRECK and should be 10 miles away from
any road or it should be crushed NOW!

>If that is correct then I think a loose steering box is able to float
>to compensate for frame movement, but that good effect will end up
>with another broken bracket. Unfortunately for my mechanic he
>guarantees his work so he has to keep repairing the bracket, not a
>happy situation for him. What would you advise him to do? Is it
>possible to reinforce the frame for a reasonable effort?

It is probably illegal to repair or attempt to repair this car.
R. Mark Clayton - 13 Jul 2007 14:53 GMT
>>On 12 Jul, 16:50, steve-ca...@clara.co.uk wrote:

> The car has NO MORE LIFE it is a TOTALED WRECK and should be 10 miles away
> from
[quoted text clipped - 8 lines]
>
> It is probably illegal to repair or attempt to repair this car.

Not if you can straighten the frame.
michaelharvey@sympatico.ca - 13 Jul 2007 18:53 GMT
On 13 Jul, 09:53, "R. Mark Clayton" <nospamclay...@btinternet.com>
wrote:
> <steve-ca...@clara.co.uk> wrote in message
>
[quoted text clipped - 15 lines]
>
> Not if you can straighten the frame.

The way I experience the car, it is a straight frame because the tire
wear is normal. There just seems to be something moving. If it is a
broken frame it might be right to be concerned about the safety. I
don't know what would happen if the frame suddenly came apart, I
wouldn't want to be travelling at high speed. Maybe it could be welded
without if it the break could be seen.
steve-caner@clara.co.uk - 13 Jul 2007 21:55 GMT
>On 13 Jul, 09:53, "R. Mark Clayton" <nospamclay...@btinternet.com>
>wrote:
[quoted text clipped - 24 lines]
>wouldn't want to be travelling at high speed. Maybe it could be welded
>without if it the break could be seen.

Welding actually weakens the area around the weld. That's why the Liberty Ships
nearly always broke in half.

It might have to be plated but I still say it's dangerous. Get it down to a
chassis/body shop with a Laser aligning jig or a BMW body shop to be checked.

IT'S NOT SAFE
Bill - 13 Jul 2007 22:49 GMT
> Welding actually weakens the area around the weld. That's why the Liberty Ships
> nearly always broke in half.
-----

Negative. They broke because of the relationship between the length of the
ship and the length of the waves at sea. It caused a harmonic motion that
weakened the ship at the midship (middle) by lifting the bow (front) out of
the water and slamming it down as the wave passed. A period of time doing
this caused the metal to fatigue. That's why the Liberty ships were
overhauled by adding a steel belt at the midships area. Welding had ZERO to
do with it. I saw the History channel episode on Liberty ships, maybe you
should, too. This is an excellent thread on mis-information. And if welding
caused weaked areas, why is it so prolific throughout metal construction of
any kind? Yeah, I thought so. Moving on...

Bill in Omaha
'86 535i
steve-caner@clara.co.uk - 14 Jul 2007 09:48 GMT
>> Welding actually weakens the area around the weld. That's why the Liberty
>Ships
[quoted text clipped - 14 lines]
>Bill in Omaha
>'86 535i

Ok Bill - wrong example but the QE2 and many other ships of equal size didn't.
BTW I did see that prog last year and remember the reinforcement belt.

The truth still stands that the heat generated when welding can and does weaken
the surrounding metal.  Generally if you look at a broken "welded" joint you
will invariably see the weld intact and the metal around it has broken showing
the weakness.
R. Mark Clayton - 14 Jul 2007 15:40 GMT
>> Welding actually weakens the area around the weld. That's why the Liberty
> Ships
[quoted text clipped - 18 lines]
> Bill in Omaha
> '86 535i

Obviously we must have watched different episodes.

Wave lengths vary at sea as does the angle of incidence of the ship, so
inevitably every ship will experience waves that will resonate with the ship
at some time in their lives.

The real reason Liberty ships sank is as follows: -

1. Material
   The steel was cheap and of poor quality, but the particular problem was
that the relatively high carbon content meant that the steel became brittle
at low temperatures, such as those experienced in the north Atlantic in
winter.

2. Welded without stress relief
   An all welded ship was a new idea, and it was not realised that once
started a crack could propagate through the entire structure.  In particular
the deck hatches were rectangular with right angle corners and this provided
a point of high stress for cracks to start from.

3. Amateur Welding (well not quite)
   Workers building the ships were relatively inexperienced (most
experienced ship builders had been drafted) in ship building in general and
welding in particular.  Tight schedules (like building a ship in three days)
meant that there was little quality assurance and welds were often weak or
defective and / or liable to corrosion.  Poor technique also weakened the
steel near the weld.

4. Poor loading
   In the fog of war the ships were simply loaded willy nilly, resulting in
increased stresses in the hull.

The net result was that cracks would start in the corners of the hatches and
propagate right around the hull and the ship would split in two.  The are
plenty of pictures of half liberty ships, and one allegedly split
immediately after launch.

That said, after relatively light remedial work (around the hatches) many
liberty ships spent decades plying in the tropics (as well as vulnerability
to cold they usually also lacked heating for the crew), and IIRC the last
one only retired in the 90's.

Early Comet aeroplanes also suffered in this way.
steve-caner@clara.co.uk - 14 Jul 2007 16:29 GMT
>>> Welding actually weakens the area around the weld. That's why the Liberty
>> Ships
[quoted text clipped - 62 lines]
>
>Early Comet aeroplanes also suffered in this way.

Didn't the tail crack off or something like that.  The other great one was the
DC-10 and the cargo door frame cracking and the 3rd engine mounts giving way????
JoshIII - 14 Jul 2007 18:39 GMT
<steve-caner@clara.co.uk> wrote in message
><snip>
>>Early Comet aeroplanes also suffered in this way.
>
> Didn't the tail crack off or something like that.  The other great
> one was the DC-10 and the cargo door frame cracking and
> the 3rd engine mounts giving way????

Or was it a Lockheed L-1011 that had the cargo door failure?
...but I think the incident I am referring to was a DC-10.
Its happened over France or Germany.   The cargo door wasn't
closed properly by ground crew.  The cargo door blew open
at high altitude.   The differential pressure between
the cargo and passenger compartments buckled the passenger
deck.   Unfortunately all the control cables ran underneath the
passenger deck,  causing the crash.

Does a 535 have a frame?     or is it unibody

JoshIII
Not UK
R. Mark Clayton - 14 Jul 2007 21:08 GMT
> <steve-caner@clara.co.uk> wrote in message
>><snip>
[quoted text clipped - 7 lines]
> ...but I think the incident I am referring to was a DC-10.
> Its happened over France

near Paris

> or Germany.   The cargo door wasn't
> closed properly by ground crew.

The cargo door had a fault, which allowed it to open in flight.

> The cargo door blew open at high altitude.

relatively low altitude.

> The differential pressure between
> the cargo and passenger compartments buckled the passenger
[quoted text clipped - 5 lines]
> JoshIII
> Not UK
JoshIII - 15 Jul 2007 21:45 GMT
"R. Mark Clayton" <nospamclayton@btinternet.com>
><snip>
>> .....   The cargo door wasn't
[quoted text clipped - 5 lines]
>
> relatively low altitude.

Just the facts:  The aircraft suffered an explosive decompression while
climbing through 11,000 feet after takeoff from Paris Orly
Airport. Due to a design flaw in the locking mechanism of the
cargo door, a ground crew member was able to force the
locking arm into position, while the door was not, in reality,
locked. Climbing into thinner air, the door was unable to
remain closed without the lock, and it burst open. The
outrush of air caused the cabin floor to collapse and
severe all control cables, leading to a loss of control
by the flight crew.
Psycho - 16 Jul 2007 19:50 GMT
Interesting, but this is a BMW newsgroup and the topic of this
particular message was 535i rough idle...

>"R. Mark Clayton" <nospamclayton@btinternet.com>
>><snip>
[quoted text clipped - 17 lines]
>severe all control cables, leading to a loss of control
>by the flight crew.
michaelharvey@sympatico.ca - 17 Jul 2007 00:35 GMT
> Interesting, but this is a BMW newsgroup and the topic of this
> particular message was 535i rough idle...
[quoted text clipped - 26 lines]
>
> - Show quoted text -

Exactly, and they told me my car was unsafe. It is not an airplane. My
mechanic said if the frame came apart, I would have lots of warning,
like shaking and whatever.
R. Mark Clayton - 17 Jul 2007 10:36 GMT
>> Interesting, but this is a BMW newsgroup and the topic of this
>> particular message was 535i rough idle...

The thread had drifted some what, although remained on the subject of
structural integrity of welded space frames

>> - Show quoted text -
>
> Exactly, and they told me my car was unsafe. It is not an airplane. My
> mechanic said if the frame came apart, I would have lots of warning,
> like shaking and whatever.

Not so, any failure is most likely to occur when the car is under maximum
stress - e.g. high speed cornering, although you might be lucky - my father
had a sub-frame failure (after I had cracked it on a hump back bridge)
severing brake pipes / cables and I had a classic fatigue failure on a
bottom link (neither BMW's) both of which fortuitously occurred at low speed
in circumstances where safety was not compromised, however it is far more
likely that failure will occur as you round a fast bend.
michaelharvey@sympatico.ca - 17 Jul 2007 19:40 GMT
On 17 Jul, 05:36, "R. Mark Clayton" <nospamclay...@btinternet.com>
wrote:
> <michaelhar...@sympatico.ca> wrote in message
>
[quoted text clipped - 19 lines]
> in circumstances where safety was not compromised, however it is far more
> likely that failure will occur as you round a fast bend.

Of course, that's not what I want to hear, as it means I will have to
part out my car. Maybe buy another of the same vintage never in an
accident and use my other for parts. Always I like to get as much
information as possible before making a decision. There should be
documentation on frame failure in old ex-collision cars, somewhere,
i.e. http://www.accidentcheck.com/. Accordingly there are millions and
millions of unsafe vehicles being driven around right now.
stuart - 17 Jul 2007 11:12 GMT
> Exactly, and they told me my car was unsafe. It is not an airplane. My
> mechanic said if the frame came apart, I would have lots of warning,
> like shaking and whatever.

That's the time to use the ejector seat
Oscar@nowhere.com - 17 Jul 2007 18:15 GMT
>> Interesting, but this is a BMW newsgroup and the topic of this
>> particular message was 535i rough idle...
[quoted text clipped - 30 lines]
>mechanic said if the frame came apart, I would have lots of warning,
>like shaking and whatever.

and the steering becoming detached from the chassis member and you heading
straight for a solid oak tree that won't bend or fall over or maybe the local
school bus stop were all the kids are waiting for a bus - go on mow them down
one might belong to you or your neighbor!

Crush the f.cking thing before it kills you
Oscar@nowhere.com - 17 Jul 2007 18:13 GMT
>Interesting, but this is a BMW newsgroup and the topic of this
>particular message was 535i rough idle...
[quoted text clipped - 20 lines]
>>severe all control cables, leading to a loss of control
>>by the flight crew.

Perhaps the moral of the story is don't go too high with the doors open!
R. Mark Clayton - 14 Jul 2007 18:53 GMT
>>Early Comet aeroplanes also suffered in this way.
>
> Didn't the tail crack off or something like that.

No cracks started in the corners of the square windows and propagated all
the way round the fuselage.  The metal was too thin as well.

> The other great one was the DC-10 and the cargo door frame cracking

Correct this was diagnosed, but not acted upon by by ?Turkish? Airlines,
whose DC10 crached near Paris, when the door came off, hold depresurised and
the floor collapsed (sucked) into the hold severing control cables.

>> and the 3rd engine mounts giving way????

This was a crash at Chicago.  Bad maintenance practice (fork lift)
overstressed mounting bolts, which sheered in service.  OTOH the plane
should have survived this.

Other 'involuntary retirements' of DC10's include: -

San Diego - instructor allowed trainee to fly a light aircraft into the
glide path and collide with DC10.

Mount Erebus (Antartica) - Air New Zealand pilot over ruled navigator and
flew below known height of terrain in poor visibility and hit the ground.
CFIT

Other notable sillies with Airbus

France - test pilot over-rode automatic at show and failed to avoid forest -
CFIT
Bangalore - 6 week old plane crashed at airport (pilot error) probably CFIT
Strassbourg - co pilot set 10X descent rate; pilot failed to observe
altimeter; CFIT
Russia - Aeroflot pilot put his eight year old son in charge of controls -
spiralled into the ground.

The last won a Darwin Award.
Dave Plowman (News) - 13 Jul 2007 22:55 GMT
> Welding actually weakens the area around the weld. That's why the
> Liberty Ships nearly always broke in half.

And you think riveting stronger?

Signature

*Go the extra mile. It makes your boss look like an incompetent slacker *

   Dave Plowman        dave@davenoise.co.uk           London SW
                 To e-mail, change noise into sound.

steve-caner@clara.co.uk - 14 Jul 2007 09:44 GMT
>> Welding actually weakens the area around the weld. That's why the
>> Liberty Ships nearly always broke in half.
>
>And you think riveting stronger?

Dave - I didn't say that.  there is welding and "WELDING" one is done by divi
Jones the work experience school leaver and the other is done by educated
professionals with years of experience.

It only need a bit of oxygen to reach the molten metal and the weld is flawed.
GAS,  MIG & ARC have always been the favorites of crash body shops and gas is
the main culprit of porous welds with ARC coming a very close second. MIG is
generally better in the hands of a skilled operator but only if there is enough
gas pressure and flow rate.

BTW 99.9% of all airplanes are riveted and they are pretty strong they only seem
to break up when they hit the ground at speeds over 300 MPH as your car would -
don't know many ships that go that fast except space-ships.
Dave Plowman (News) - 14 Jul 2007 10:01 GMT
> >> Welding actually weakens the area around the weld. That's why the
> >> Liberty Ships nearly always broke in half.

> >And you think riveting stronger?

> Dave - I didn't say that.  there is welding and "WELDING" one is done by
> divi Jones the work experience school leaver and the other is done by
> educated professionals with years of experience.

So those ships were welded by amateurs?

Signature

*Succeed, in spite of management *

   Dave Plowman        dave@davenoise.co.uk           London SW
                 To e-mail, change noise into sound.

steve-caner@clara.co.uk - 14 Jul 2007 16:26 GMT
>> >> Welding actually weakens the area around the weld. That's why the
>> >> Liberty Ships nearly always broke in half.
[quoted text clipped - 6 lines]
>
>So those ships were welded by amateurs?

Possible - there was a war on.....................?
michaelharvey@sympatico.ca - 14 Jul 2007 04:50 GMT
On 13 Jul, 16:55, steve-ca...@clara.co.uk wrote:
> >On 13 Jul, 09:53, "R. Mark Clayton" <nospamclay...@btinternet.com>
> >wrote:
[quoted text clipped - 34 lines]
>
> - Show quoted text -

What would actually happen if the frame came apart? Would the front
tires suddenly splay outwards bringing the chassis down to the road,
or would the chassis hold it together for a while where bolted to the
frame?
 
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