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...