Frame Rail repair "cap"

famous bob said

MY frame ad a crack in it around one of the K frame holes, I welded t up, ground it flat, and made a frame cap for that area, and a matching for the other side. Then put front support bars in the engine bay, along w/ a 6 point cage. Pretty stiff for a streetcar.

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They can work well as a gusset. But for their intended use of rust repair they’re not a good idea.

And like anything they depend on the prep. If you remove all the rust and paint everything with an etching primer or weld through primer it’s a different story. It also depends on how well you fit them. But adding layers over weakened rusty metal is a temporary fix at best.