How would you remove/repair this rust?

Just got done greasing my u joints and was shocked to find my frame rusting from the inside, near the front part of the frame where it becomes fully-boxed.

I know rust issues are common on our trucks, but I always obsessively took great care of this truck. It’s never been driven/parked near salt water and I washed and waxed it weekly when it was my daily.

How would you repair this? I’m not sure how one would properly remove the rust since it’s such a tight fit in there. The passenger side is much worse than the driver’s side, I’m assuming due to the AC drain (I should have relocated the drain.) However I address this, I want to make sure it’s a good-quality repair that lasts for the long-term, as I plan to keep this truck for many, many more years.

Truck info for those curious:
2010 Access Cab TRD Off-Road
Original owner
22k miles
No aftermarket undercoatings
The rest of the truck is pristine. No other rust on other parts of frame or on body.


Photos of the rust. Passenger side frame rail (looking toward the front of the truck where it goes from c channel to fully-boxed)



Driver’s side:



And a photo of the truck since we all like photos lol



Thanks in advance

 

I'd probably go to home depot and find a long round flexible brush to shove into the frame and try to break that flaky paint off. Then give it a good rinsing. Let it dry thoroughly for a day, maybe use some compressed air to blow it out. Then tape off the frame holes and use eastwood's internal frame coating to paint the inside. Supposed to be an all-in-one. It comes with a special hose to snake through the frame and paint it thoroughly.

https://www.eastwood.com/eastwood-i...8vU5hVsk0UUj8qOETwn3DcRa2I0YMxWxoCcNEQAvD_BwE

 

Damn . Need to check mine now . Like whatstcp said scape as much as can and also try to chip off all rust scales you can( long pry bar etc.) . Rust will keep forming under the rust scales . Worked by ocean by airport (Honolulu ) and man amazing how much rust can develop under rust scales . That eastwood internal frame coating looks like good stuff . Only problem is shipping to the islands .

 

I'd get some Fluid Film and hose it up in there. I spray mine a couple times a year and sometimes follow up with some Liquid Wrench rust inhibitor or something with a little lower viscosity.
I think it's important to do it while it's still warm outside so the fluid/spray can wick into the sandwiched areas of the frame.
Before I knew this was 'a thing' I used to do this with WD-40. It's not much but I did this pretty regularly on my old T-100 and it's still rolling around Des Moines with my nephew today and has well over 300,000 miles on it.
I even spray up into my rockers, cab corners and door weep holes. I also hose down my rear leafs and some suspension components from time to time. For that, I use the Liquid Wrench or something a little thinner than FF.

 

Fluid Film.

 

FWIW, the previous owner of my truck lived on a gravel road. The frame, cross members, spare.....complete undercarriage was covered with caked on dust, rocks, straw, sticks.....debris.

I spent several hours under the truck digging out the cake. First used a water hose with a nozzle to get the bulk. Then after a couple days used a shop vac and multiple tools to access the places beyond finger reach.

I suggest to keep the undercarriage clean. Reason, dirt will slow the drying process and keep the areas wet. This just helps rust get a foothold.

BTW, it was scary the amount of crap that was removed. Fortunately, the frame is only a couple years old and remains in good condition.

I live in snow country, so road salt/brine is common. I will make a habit of thoroughly cleaning the undercarriage each Spring. I won't be able to stop rust, but I can slow it down.

 

think you need to be asking @GQ7227

 

i am so cursed

 

Appreciate everyone’s input!

Think I’ll give Eastwood’s a try. Sounds like the perfect solution to get deep into the nooks and crannies of the inner frame.

Still can’t believe this rust has been lurking in there.

 

i am currently treating my old taco to that product, the green stuff

it will dry near instantly on the crusty when it touches, it has very low viscosity to creep into crevices better, so it WILL run like a river on any 'normal' painted surfaces

this is also a magnet tool i found helpful to dig out loose coating and crusty specs

$9 Master Magnetics Bendable Magnetic Pick-Up Tool and Retrieving Magnet, 19” Length, 2 lb. Hold 07229

https://www.amazon.com/gp/product/B000H5QRV4/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1
its also very strong, will lift a full jar of cinnamon right off the table several inches
so far it has not snapped on me with the bends and twists it has been subjected to

 

Hope they ship to Hawaii. Like to try that too.

 

That magnet tool will be a big help in getting the crusty stuff out. Appreciate the suggestion.

How many coats do you plan to spray on your frame?

 

Wow, appreciate the great info! Can’t beat real-world field testing. Looks like the Eastwood internal frame coating and fluid film may be my best bet.

 

Had some time after work today, so out of curiosity I checked under my other 2nd gen, a 2008 regular cab. I was surprised that it wasn’t as nearly bad as the 2010. I regularly use the 08 off-road and it’s frequently been driven to the beach and near salty air.




I also checked under my father’s 2007 DCLB and it had quite a bit of rust. For the 07 however, the bulk of the rust was on the outside of the frame, near the front cab mount. Also saw some on the inside of the c channel section of the frame under the doors. The 07 is a farm truck and pretty much only used on hard dirt roads and the highway. I should have taken photos, but unfortunately did not.

For anyone reading this, check your frame! It’ll only take a minute and you could save yourself from a potential headache down the road.

 

Salt will do it.

 

You live on a volcanic rock sticking out of the middle of the largest salt-water puddle on the planet; how do you not drive it near salt water? You don't have to park on the beach to be in a high salt environment.

Good looking truck, and I have a question. Is the grill a stock item? I have a 2011 and would love a grill center with TOYOTA spelled out instead of the emblem with all the ovals. Where do you find that?

 

Cool tool though the two pack ain’t no bargain.

 

you sprayed the CorrosionX HD inside an internal frame cavity?

 

Yes

 

2 passes with the green, and am planning to final coat with the black IFC so that it might be easier to scope it out down the road a number of years and see how its still holding up and not peeling or anything weird
the included wand did miss some spots. even on two passes. and I have to carefully use a straw to touch some of this up in corners
but i don't know if your internal frame has these big support braces whatever pieces in the middle throughout the channel?