Yet another rust story - how screwed am I?

I found the worst rust between the gas tank and the inner frame. That was where a screw driver broke through. The inner section of the frame is thinner than the outer section. Also, swing the hammer hard on that inner section of the frame. Tapping it isn't enough, you are looking to see how the hammer reacts to the known "good" frame and then hit the other sections with some force.

Another option is to look at the time and effort to restore the frame versus going the route of replacing the bad metal. I am pleased with the safe-t-cap product. Cost about $1700 to install both the left/right sides with two sections at a local shop in Wisconsin. If you have family who owns the shop maybe you can get a deal and just give you piece of mind that the old metal is out.

http://www.autorust.com/product-category/toyota-tacoma/tacoma-doublecab-4wd/

 

There's an example of rust perforation on a frame. What is that though? Doesn't look like a Tacoma. Tundra?

 

Classic example of a frame that has rusted through from the inside.
Exterior looks ok, still has paint, but you can see how badly rusted it is inside where there is missing chunks of frame

 

was a regular cab 01 tacoma. 2wd

 

These pics are horrifying to look at. Such good, sound, reliable trucks in almost every way and some idiot botched the frames.

 

Ah ha. I've never been under a 2wd reg cab.

 

If you are staying in cali just clean it up and paint it. Not even any holes.

 

Mine had surface rust all over like the OP and I bought it anyways knowing that I was replacing the suspension etc. Took a couple weeks but I stripped out all the suspension and exhaust and then went over the frame with a needle scaler to knock off any loose stuff. Used a brush and did 2 good coats of POR15 and frame looks mint now.

While I was at it I also added the Trail Gear outer frame plates and boxed in the rear front spring mounts.

 

Nope, once repaired and restored (I'll do a different thread for that) I'm driving it back to Virginia.

 

Progress Update
My brother's team applied Loctite Rust Disolver to the frame, brushing it on and letting it sit, then power washing it off the next day. The results were great; a little pitting but in general the frame is coming along well.






Still a lot of work to do, this is just the first round of prep. Looking for a used rear end / leaf spring setup from a clean Cali truck now to replace a lot of the non-frame parts in the rear end.

 

looks good! Pitting isn't really a big deal, as it will actually help the paint adhere to the frame. The most important is that isn't rusted through

 

Also, heard back from Toyota today. They said that since my truck was never taken in for the frame campaign to seal it (ended in 2011) I was no longer elegible for the 15 year extended warranty. Oh well.

 

yep, this is one of the requirements you (or the previous owner) had to meet to have the truck eligible for a new frame :/

 

Yeah, I really should have gotten that done back in 2011, 6 years before I owned the truck.

 

Your frame looks good, rust converter inside~out, and a coat of epoxy paint and you should be good to go, after all of that, annual touch ups will keep you safe.

 

OK, some more pics. PS - Any suggestions on where to get a replacement gas tank skid plate? I'm looking to armor the bottom anyway, though most of the aftermarket guys seem to only go back to 2005 (this is a 2003 double cab off road). Any recommendations are much appreciated!

 

If you're looking to really armor the underside of your truck, the OEM skid plates aren't super tough. They are more like debris deflector than real armor.

Sure, it's better than nothing, but they aren't the best ones, as they are quite thin

Is your skid plate rusted through? if not clean it up real good with a wire brush, some rust killer, then some paint and put it back.

Or you can fab your own

 

I suspect that your frame is to good for replacement. After you cleaned it up it looks quite good. For replacement your frame would have to have holes through, which yours doesn't have.

 

Thanks onakat - you've been super helpful! For the gas tank I found an aftermarket gas tank plate from Low Range Off Road. Still shopping around for a decent skid plate for the front. While fabricating my own sounds cool, I'm counting on my brother's shop to get this work done so it's easier to just buy one and ship it to him. Still looking!

 

Also want to suggest that when the paint (which ever you decide to use) is fully dried/cured, spray the crap out of it with Fluid film. It will compensate for any locations that paint can't fully cover/protect. Also don't forget the inside of the frame rails. I used the green phosphate internal frame coating from Eastwood. (then FF each fall)