Frame Rust Repair Options (1 Viewer)

[BurrBurr]

During a state inspection, I discovered a small rust hole on my 2001 frame next to to left rear wheel. It doesn't look too bad, but the inspection shop won't pass the truck without getting it repaired.

The rest of the frame is in good shape, only surface rust. I might end up going to another shop for a second opinion.

Has anyone else experienced this rust in the same spot? What is the best way to repair it?

 

[FxFormat]

Cut a square patch around that, cut a piece of 3/16 steel plate and weld it on, then treat it with some paint

 

[3_puppies]

it really depends on how the surrounding metal is.
you could just have a patch welded over the top of it,
to get by a square can be cut out and a replacement piece welded in,
you could find a good replacement and have the entire crossmember replaced

 

[Kabanstva]

Don't you guys just hate rust! It's sad to see what all the salt is doing to these trucks.

 

[notgivupmy98lc]

I had a 1998 in Pennsylvania through 2010 and then have been in Massachusetts since where salt/chemicals on the roads are ridiculous. I started failing inspecting with holes in frame a few years ago. Body on frame vehicles are essentially dissolving up here and you can't drive by a Toyota dealer without seeing a new frame (Tacoma's mostly) being wheeled into the service garage. I found a local welding expert who patched me up - that was 3 years ago. Last year I found a place near Concord NH who does an oil film treatment ( NH Oil Undercoating | Vehicle Undercoating Services & Products ). The most serious problem I found with the rust is brake line failure. If you get brake lights or soft pedal and have rust like yours (mine) might want to do the lines before they fail while driving (like me).

 

[RWWLAW24]

Will look like this when you clean it up. I have an appointment with my welder.

 

[Alibaster]

Look for a rust repair place, they usually will do coating and patch work. Where are you located in PA? I have used a shot locally to me (Pittsburgh area) for other projects that does good work at affordable prices. When my LC eventually needs it they'll be the place I go to.

 

[Automatic]

I just bought my 100 about a month ago. It started its life for 7 years in Colorado. When I got under it to check it out I noticed rust in the same spot but maybe less flaked off than your photo. Today I took a hammer to it and it went straight through. Pretty shocked since it didn't look so bad initially and the guy selling it to me said it was just some surface rust. Any updates from the OP on how you treated it?

 

[Kabanstva]

I just bought my 100 about a month ago. It started its life for 7 years in Colorado. When I got under it to check it out I noticed rust in the same spot but maybe less flaked off than your photo. Today I took a hammer to it and it went straight through. Pretty shocked since it didn't look so bad initially and the guy selling it to me said it was just some surface rust. Any updates from the OP on how you treated it?

View attachment 2355351

Is that hole only on the driver side of the crossmember? Passenger side looks fine? I wonder why. That’s two trucks with bad rust in the exact same spot.

 

[FxFormat]

Is that hole only on the driver side of the crossmember? Passenger side looks fine? I wonder why. That’s two trucks with bad rust in the exact same spot.

Salt and chemical gets in the frame, truck gangsta lean to the left because of gas tank, traps it and rot from the inside out?

 

[Kabanstva]

Salt and chemical gets in the frame, truck gangsta lean to the left because of gas tank, traps it and rot from the inside out?

That’s very possible. I guess now that these salt belt trucks are getting pretty old, we can see where all the weak links are. So far it seems like the passenger side front sway bar bracket is a definite weak link (guessing the combination of salt and AC condensation always dripping into the mount), and now this second to rear-most crossmember area seems like it’s showing its weakness.

 

[Somebodyelse5]

That’s very possible. I guess now that these salt belt trucks are getting pretty old, we can see where all the weak links are. So far it seems like the passenger side front sway bar bracket is a definite weak link (guessing the combination of salt and AC condensation always dripping into the mount), and now this second to rear-most crossmember area seems like it’s showing its weakness.

That's where condensation from your AC drips... even mine in AZ had rust there.

 

[CLEcruiser]

Being from OH , it's crazy to me they won't let you drive your car because of a little rust hole like that.

 

[Automatic]

Is that hole only on the driver side of the crossmember? Passenger side looks fine? I wonder why. That’s two trucks with bad rust in the exact same spot.

Yeah, driver's side. I'm now so paranoid that there's parts of the frame that are rotting from the inside out that I juts can't see. I just posted in the 'Ultimate Rust / Undercarriage thread' looking for some responses. Hoping someone can tell me that this is a common spot and that I don't need to overly worry since I don't live in a place with salt on the roads. Obviously that answer may not exist though.

 

[Mike NXP]

Flexseal

 

[ClassyJalopy]

Mine had a rust spot start appearing at the exact same spot. I took a wire wheel to it and then just Rust Reformer followed by paint.

In your case, I would grind that spot and then shape it like regular hole and paint over it. Take it to the next shop and they won't even notice it!

 

[De La Cruiser]

I just bought my 100 about a month ago. It started its life for 7 years in Colorado. When I got under it to check it out I noticed rust in the same spot but maybe less flaked off than your photo. Today I took a hammer to it and it went straight through. Pretty shocked since it didn't look so bad initially and the guy selling it to me said it was just some surface rust. Any updates from the OP on how you treated it?

View attachment 2355351
[/QUOT
i thought mine wasnt as either went back and....

 

[De La Cruiser]

Will look like this when you clean it up. I have an appointment with my welder.

View attachment 2118765

.....

 

[De La Cruiser]

Will look like this when you clean it up. I have an appointment with my welder.

View attachment 2118765

Do you have picks afrer they made the repair?

 

[feza]

I have a small rust spot on the cross member like everyone else, when I was fluid filming inside the frame in that area I discovered a rodent nest full of pink insulation up in the frame there.