misterfixit
Old School Hero
You can’t weld over the crack any where where there is going to be tension. You have to cut out the crack and rebuild with weld. It will need careful thermal control so you don’t get odd stresses, then it will need treating after. Old parts made of aircraft series alloys that have been highly stressed have to be treated very carefully. They exhibit stress corrosion cracking. this can originate from any imperfection under stress, and the failure mode is a crack that self propogates.You don’t necessarily have to write that frame off.. I’ve had cracked ally frames re-welded in the past without any problems. Drop it off with a couple of bottles of beer/cider to your local fabricators and ask them to run a bead of fresh weld along the crack. Chances are they’ll do it in their lunch break for £10-20 and you’ll be away.
Good luck.