FAAC Welding & Fabrication Nationwide

FAAC Welding & Fabrication: The Lewisville Owner’s Guide

We stock FAAC-compatible welding and fabrication parts on the truck and can typically weld, refabricate, or replace a failed FAAC gate component in Lewisville the same day we diagnose it. Installed pricing for most FAAC welding and fabrication work runs between $225 and $650, depending on whether we’re repairing the existing steel in place or fabricating a new bracket, hinge mount, or reinforcement plate from scratch. The way most Lewisville owners discover the problem is simple: the gate starts sagging at the hinge, a weld cracks at the operator mount, or the gate post itself shifts because the steel underneath finally gave out after a decade of Texas heat cycles.

Call (817) 826-9477

What separates one weld from another isn’t the machine, it’s the prep and the match. FAAC operators put torque through very specific points: the piston bracket on swing gates, the rack mounting on slide gates, and the hinge plates where the leaf’s full weight transfers to the post. When those points crack, the fix has to address why they cracked, not just lay bead over the fracture. In Lewisville, the usual culprits are rust at the post base from irrigation overspray, and fatigue at the weld toes from years of wind loading across open driveways. We’ll name exactly what failed before we touch it, and the price lands in writing before any work starts.

Which FAAC Models This Applies To

This applies to the full range of FAAC residential and light commercial operators we service across Lewisville: the 400 Series swing arms (including the 402, 412, and 415), the 390 and 391 24V hydraulic operators, the 770 and C720/C721 slide operators, and the newer 740 and 844 series boards paired with articulated arm kits. The welding and fabrication side of the work doesn’t change much from model to model because the failure is almost always in the steel, not the motor. What changes is the bracket geometry: FAAC hydraulic operators mount differently than their electromechanical siblings, and the mounting plate for a 390 sits at a different angle than a 402’s bracket.

Here’s the compatibility gotcha most Lewisville owners don’t know until something breaks: FAAC uses metric bolt patterns on their mounting hardware, and generic gate bracket kits sold at big-box stores are drilled for imperial. If a previous repair used an aftermarket plate with slotted holes to “make it fit,” the operator has been fighting slop at the mount for years, and the wobbly motion is usually what cracked the original weld. We fabricate to the metric spec and bolt-hole center of the specific model, so the operator sits square and loads the steel the way FAAC designed it to. On the OEM versus aftermarket question: for raw brackets and hinge plates, quality domestic steel fabricated to spec is usually a stronger choice than OEM stamped parts, but we’ll show you both options and price them side by side before you decide.

Signs Your FAAC Welding & Fabrication Is Failing

• The gate leaf sits visibly lower at the latch side than at the hinge post. This nearly always means the lower hinge weld or the hinge plate itself has begun to tear under the leaf’s weight, and the gap is opening a little more every week.
• You can hear a metal-on-metal grind or a rhythmic knock when the gate runs. A broken weld at the operator mount lets the piston or arm flex against the bracket with each cycle, and that flexing sound is the steel telling you the crack is expanding.
• The gate shudders or skips for a moment right as it starts moving. A partially failed mount creates a brief interval of no load before the operator picks up the gate, and that hesitation reads as a jerk you can feel through the ground.
• Fresh rust streaks run from any weld joint, especially at the post base. In Lewisville’s clay soil, sprinkler water wicks up the inside of a gate post and rots the weld zone from the inside out; by the time you see the streaks, the joint is structurally suspect.
• The gate post moves when you push against it by hand. If you can rock the post even 1/16 of an inch, the weld at the post’s base or the embedded steel core has failed, and the operator is now flexing the entire assembly every time it cycles.

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After

Replacement Cost & What’s Included

In Lewisville, basic weld repair on an existing FAAC bracket or hinge mount runs $225 to $350 when the surrounding steel is sound and we can re-weld in place. Fabricating a new mounting plate or hinge bracket from plate steel runs $350 to $650, depending on material thickness and whether we need to remove the gate leaf to access the work area cleanly. Full post replacement with new steel and a fabricated base plate lands between $500 and $900, which includes setting the new post in concrete and re-hanging the leaf to factory alignment.

Every price we give you is a written flat price before we strike the first arc. It includes our assessment of why the original failed, the weld itself, grinding and finishing, primer and paint or cold-galv coating on every repaired joint, and a photographed record of the finished work under Haven Standard Clause 4. You’ll see the part number, the material spec, and photos of the weld before and after coating. The work is covered by our 365-Day Done Right Promise: if any weld we make fails within one year, we repair it at no additional charge.

DIY or Call Us?

Here’s the honest split. You can safely check the hinge bolts with a wrench, watch for the symptoms listed above, and take photos of any cracks you find before calling us. That documentation actually helps, because it shows us the crack as it sits under load on your gate, not after we’ve taken everything apart. What we don’t recommend is breaking out a flux-core welder from a box store and laying a bead over a structural crack. The steel in a gate hinge or operator mount carries the full weight of the leaf plus the shock load every time the operator starts and stops. A cold, shallow, or contaminated weld in that location creates two problems: it hides the original crack under a layer of new metal, and it leaves the repair holding on surface area alone while the fatigue crack continues underneath.

If the failure involves the welded joint between the gate leaf and its hinge pin, or any bracket that carries the operator’s push and pull force, that’s a structural weld under live load. A failed repair there can drop a 400 lb gate leaf without warning. That’s not a scare line, it’s the physics of the assembly. If you suspect a failed weld, call us at (817) 826-9477 and one of us will come out, inspect it, and give you a written price before anything gets touched.

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