So I was fixing my rear brake issue and noticed that the steel of my frame rearward of the rear suspension just didn't look right. More than surface rust. I started tapping it in places and it didn't sound right either <img src="/forums/images/graemlins/frown.gif" alt="" /> So decided to find out how advanced the problem was with a hammer and a chisel, and said WTF many times. Take a look <img src="/forums/images/graemlins/frown.gif" alt="" />

Drivers side









Passenger side





That pile of rust under my truck mostly came from the inside of the frame rail. ALL the frame forward of this is like a frame from another truck in the it's in perfectly good shape and no rust. I can only assume that this truck was used to launch a boat with the back end of the truck in salt water or something like that.

Sigh...I'm not worried about cutting back to good steel and welding in some plate (although I am worried about the amount of rust that fell out of the frame rails in terms of strength), but I need to stop it getting any worst. Anyone know what I can spray into the frame rail, to seal it, that will not catch fire when I weld it?

Also there's the gas tank right there. Should I remove it or is it OK to weld up the frame with a welding blanket over the gas tank?

Thanks in advance. I'm pretty pi$$ed, but that's life I guess...

Holy crap is right. Wow. Yeah, I wonder if the truck was used to back a boat down into salt water. I dont like rust.

And that is a 97? I would almost think you were up north here but I have not even seen an 87 that bad. Heck if you told me that was an Izusu I would expect that. It is good you don't have state inspections down there.
Welding next to a tank is no issue. Just make sure there is a top on the tank first.

Whewh...

If it were me, I would consider getting a sawall on the frame of a truck in the junkyard, and patching good frame into yours.

Yeah, I've been thinking the same thing. It's the rot on the inside that concerns me. Then I though about swapping the rear of the frame with a body lift on the rest of the truck. You know like cap did <img src="/forums/images/graemlins/smile.gif" alt="" /> I don't know. May be I should just get Gen 3 <img src="/forums/images/graemlins/frown.gif" alt="" />

Yeah.. Do this. Then you REALLY have an excuse to get rid of that rusty stuff!

I think McV ran a small mop soaked in POR15 through his frame? If you cut a section out, you could do something like that maybe.

I was about to recommend POR15 also. Bretwalda (phil) did this to his front suspension and it looked Awesome, just had some issues getting everything lined up again. But I'd consider doing that to the rear. But if you decide to go a lil more extreme, cutting the rear off like Carlos did would be the way to go considering all (i think) the rust would be on the frame that you'd cut off. After its cut off, you could coat that thing in POR15, patch it up and never worry about it again.

Damn Reuben, thats scary looking! <img src="/forums/images/graemlins/scared.gif" alt="" /> Good luck <img src="/forums/images/graemlins/kewl.gif" alt="" />

Angelo

If you have access to a spray gun, POR-15 can be thinned out enough to spray. That stuff is like magic on rust.

Thanks guys. I think I will use POR-15 on the rest of the frame, which has no issues, but... I am looking for another frame to chop up. I think it's too rusted on the inside and so if I patched it up I would simply be welding a nice patch to crappy, rusty steel on the frame. Not much good.

Not sure if I should do a 1" or 2" body lift. I can't see me using tires bigger than 33's so may be a 1" is fine. I may lift the gas tank in the frame too while I'm at it. <img src="/forums/images/graemlins/smile.gif" alt="" />

If only I had more time on my hands <img src="/forums/images/graemlins/rolleyes.gif" alt="" />