The Accident
As T4R2014 so sagely pointed out, the front end has some bumper issues that would point in the direction of an accident.
What I found was nothing short of amazing.
In test driving the vehicle, I did get it out on the freeway, and at speed (upwards of 80), nothing squirrely or weird, handled fine.
Post purchase, and some days later, I crawled underneath the vehicle to get a better look at what might be leaking and found this when I got a good look at the frame member:
At first I said :wtf: the frame is cracked, but as I stared at it in disbelief (and had a good friend who is way more car savvy come over and take a look), we find that it wasn't cracked, but was cut, on both sides, and then crappily welded back in place, and then slathered over with bondo. And the crappy welds didn't hold.
Are we having fun yet?
My good friend has built his share of rally and race cars, so I deferred to his judgment as to what to do. He said the wheel alignment is only slight off, with plenty of adjustment left, so reinforcement would be fine.
I said I'd do the work if he directed my efforts.
After a couple nights in the damn cold, under the vehicle with an angle grinder, here is what I prepped:
The next step, I bought a 1/4" steel plate roughly 2 feet by 8 inches, and using cardboard made a template of the frame member.
Then traced the frame member onto the steel plate, cut it out with a plasma cutter (added a couple of round holes, so we could put in some rosettes), and then welded it into place:
So the finished repair, with frame paint (still wet in this photo).
Good deal..... to be continued.
Riggsy