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The 1st and 8th picture are the same weld. Looks to have been repaired. All others I wouldn't be worried about.

Nice looking weld there. Next time try welding with some metal core weld wire and see how more silica is on the surface of the weld. Then maybe you will understand what is going on at that factory.

Looks like a buildup of silicon slag, normal in GMAW process, even with shielding gas. is it a reason to be concerned, no. Could you touch up with a rust preventive paint, sure you could.

Looking at this it seems to be only a JK issue, also looks to be a issue with the UNDERBODY structure. Not the frame structure everyone os worried about.

Every new vehicle launch has it's issues. Apparently you have never worked in manufacturing. NO new vehicle is perfect. I don't need to display my angle. I know that the facility does make a good product, not everything can be caught during inspections of mass produced products.

Are you are talking about current model colorado/canyon? If so dana doesnt make those now, Metalsa does currently.

I can understand your hesitation for trusting my opinion. But I've seen this line run, and the people working this line are putting in 12 hours a day to correct issues and still meet customer demand. Every new product has some issues in the early stages.

It is actually really easy and doesn't take much time. To repair many of these welds. That's not a crack, weld looks to be off seam. Truthfully I wouldn't have any issue with hopping in any of these jeeps and driving them to any destination.

JK is not galvanised. Welding galvanized materials with the GMAW process bring new issues that need new tetechniques to solve. FCAs decision to change to this material is why there are problems.

Overall nearly all of these welds would pass a cross section, Now to break down a couple of them: 2- Obviously the robot over lap wasn't spot on. 9- That indentation is a locking lance for assembly of the rail. Sets the depth for when the rail is assembled before welding. 10- Engineered skip...

You will still have silicon slag from the GMAW process. Plus this frame is 80% galvanized, so those impurities are coming to the surface during welding.

These frames are submerged in a tank to be coated, just like the JK frame.

The entire frame is dipped into a tank thus why the bottom of the frame is coated. Frame is dipped to coat the inside where its more difficult to clean and where salt, dirt, sand, ect could accumulate. Just because FCA is charging 1500 to ship the unit doesn't mean anything. FCA buys all parts...

I bet there is 140 to 150 foot of weld on this frame. Do you really think its cost effective to have people or even robots to try to chip or brush slag off every frame? I bet the assembling plant is kicking out 1000 frames a day just to try and keep up with Toledo. And all for a little bit of...

FCA spec is 6.4mm (sum of diameters) per 25mm of weld.