SAFE-T-CAP INSTALL

Hi all-
im in the middle of an install of the safetcap mid frame section,
i got the driver side tack welded on yesterday, i should get the passenger side on today.
I'm doing the install the way the instructions say, with the bed on so as not to warp frame, what a pita.

I'm planning on removing the bed after all is welded on in order to treat/coat the top of the frame.

i found more rust than i thought in the center frame, so I'm thinking I'm going to go ahead and do the center safetcap section too.

does anyone have any suggested additional repairs while I'm here?
fuel pump is new,
truck has old man emu
muffler is getting ready to rott, but I'm thinking wait until i do my NY inspection.

thanks for any advice,
i love this forum, it has been really useful,
charlie

 

Maybe make some new Spring Hangers .

Hard to tell till they are cleaned up .

 

If you mean the leaf spring hangars the safe t caps have shiny brand new ones.

 

I’d cut out as much rust as possible. Keep in mind, you can’t weld to rust but I’m sure you know that already. You could also drill holes in the replacement part and plug weld for a bit of added strength along each side provided there’s something to weld to. I’d also treat the inside of the frame before welding and then after with a cosmoline or Eastwood product.

 

I cut 1" off the top of my mid section caps and beveled to 45° which allowed welding overhead without bed removal. I highly recommend Corroseal and a 360° wand extension on undercoating gun to spray inside box frame AFTER all welding is complete. Good work saving another 1st gen.

 

Thank you for that-
I’ve got the Eastwood interior frame spray, The platinum chassis paint, the black rust encapsulater, and the chasis satin black, phew...
It’s going on one week, thank good for my in-laws kindness, driveway, and them being in Florida while I do this project-
I’ve got the rear section of the frame coated with the Eastwood platnum, and top coated with the extreme chasis black paint-
The safe-t-cap is welded in a place,
And the topper and bed are removed.

big bummer is two of the six bed bolts are seized, so I’ve been messing with those, and my buddies miller multimatic 200 mig gun trigger burned out, it’s not a stocked item anywhere so I can’t do any welding on the center section of the safe-t-cap until hopefully Tuesday at the earliest.

here’s the pics...

 

Good idea to cut off 1” of the safetcap before install- wish I would have thought of that-
Maybe I’ll do that before I do my center rail sections once I have the new trigger for the multimatic-

 

Looks like you know what you're doing. I had a cheap harbor freight flux core mig that worked well on the 11 ga. Caps. Till the wire ran out. Had to wait 3 more days to finish welding. Amazon rocks.

 

So how are the safe-t-caps holding up for you?

 

Nothing's really changed except being able to pass state safety inspection. I'm pleased with the results so far. I bought my Taco in 04, got an offer from Toyota to buy it back for full sale price in 06. Got the Frame TSB letter in 08 and had dealer applied CRC. I popped a hole with ball peen hammer 7/18 and got to work extending frame life shortly after. I have to drive through salt water to get home on extremely high tides. So I keep Yodas frame soaked in Fluid Film inside and out.

 

Here’s some updates, after the mid section safetcaps installed. I had time while waiting for parts to degrease the front part of the frame in order to look for more corrosion (I did find a little bit, nothing I need to do now)
Mid section went in well.

 

Looks awesome man! Getting ready to do this to the whole back end on my 1997. Any hardware you recommend replacing while there? Bed fasteners? Gas tank hardware? Thank you in advance. Keep up the good work!

 

If I am doing the Frame all the Hardware Gets replaced because in my case it mostly breaks or is so rounded to reinstall.

Then I have most all the new hardware on the shelf for the job.

 

Understood. I have an awesome hardware store right down the road from me, so I'll probably just be making multiple trips.

 

What Wyoming said- have the hardware ready to go. I replaced with stainless bolts. Sorry for the late reply, hope it went well!!
Post some pics!

 

So this is still holding up 4 years later, unfortunately there is more rust on another front, the battle is being lost…

 

may be worth a trip to the southern states for a rust free frame from a scrap yard

 

I am not sure, and am feeling like it's time to part this thing out. I know I won't be able to do the cab changeover by myself. also, the frames seem like they are becoming harder and harder to find.

 

Little late to your thread but did you end up parting it out already? Would be interested to see some pics of where the new rust battle is. I just did a frame swap on my rusty '01 in the driveway and it was a hell of a project, but from your earlier pictures your truck looks to be in pretty good shape. Might be worth saving.