04 frame rust

This is a tough question, I looked at those. If you have the space and skill, I'd find a frame (I found one on Craigslist for $500 when I was looking), clean it up and rustproof it, then switch over your truck onto it. It doesn't look like rocket science, just alot of work:
https://www.youtube.com/watch?v=Urqq8FbVvb0&t=503s

 

it's 5 months past his 15 year warranty... he didn't say it was treated

Safe-T-Cap would just be a band-aid at this point, you are correct that it would just get worse over time

 

That's a beautiful truck, hope you can find a way to save it.

 

it's not a "recall" so be careful on the terms. it was a "technical service bulletin (TSB)" for frame rust issue.

unless you were in or registered in a "cold weather" state the goop spray was not required

 

also, unless it was a left-over lot truck the last production was August for the 1st Gen. Chances are everything is moot when considering checking VINs anymore. sorry @Zurovetz but I hope you can find a replacement frame. chances are it's going to be cheaper in the long run to do a full swap.

 

good to know you do not necessarily have to remove engine and transmission!

 

I'd try fighting with them some about the date. Does suck you've had it sitting around from the date it expired. That was a 10K dollar decision.

 

Check out the frame repair Safe T Cap https://www.autorust.com. Good product!

 

That's a tough spot to to repair without removing the cab. Plus, it looks like there's nothing left to weld to even if you could access it. So, Safe-T-Caps may not do you any good.
How widespread on the frame is the problem? Looks like your rear bumper is sagging. Is that also from frame deterioration?

 

No, backed into something and pulled it back as best I could. That’s the only spot that’s very bad externally, I’m afraid if I started trying to weld on the frame I’d blow giant holes in it