Frame rust repair - worth it or walk away?

Preheated around 300 degrees and hang it vertically. Raise powder conveyance air and decrease assist air. Low kV, and a nontextured powder. Powder will stick to the hot surface, but above a certain thickness will limit heat transfer and powder won't stick anymore. I find 300 to be the sweet spot, though 250 may also be good depending on approach. At 350 you get enough powder that it begins to run and drip, and at 200 you lose the adhesion that heat provides. Also, a lot of the rear frame isn't boxed.

In any case, if you have access to both sides of the boxed portion it's easy enough to sandblast and coat if you think it through.

 

Are you proposing to do the whole 1piece frame this way or powder coat small sections then weld the powder coat and reapply powder coat over welds ?

 

Just powder coat the back half that you would be splicing in. Mask off an inch or two to leave clean for welding. This assumes you are splicing into a not rusty part of the frame, so just spray paint will be fine there.

 

Body looks good. I'd look into a new frame if possible and keep that baby on the road!

 

Mine was way worse , if ya like the truck get it done. If your not a welder and dont want to learn.... have someone do it for ya.......shop mechanic, or a friend of a friend. You can save yourself money and take the bed off yourself, only need one other friend to lift bed off, its 4 bolts. My spring shackle is up inside the frame.

Your truck has a little over 100k wow ! That truck has alot of life left in it. Do it !!

I safe T capped my frames at 300, 000 miles.

 

I am in the process of restoring my 96 at the moment. It's a bit of work. But if you have the ambition, you can do it. It's not smart work, its hard work.

 

It looks like it's only the rear section. That's the easiest to repair/replace. From the pics, the rest of the truck looks to be in very good condition. With the help of two friends, you can have the bed off in under 2hrs. At least do that and take it for some estimates if you don't want to tackle it yourself.

My vote, definitely worth fixing, or selling to me at a bargain price!

 

Hey, no, I called dibs

 

As said above this can be fixed. I have a 96 that had similar damage to what you have posted. It is time consuming to do it the right way but I have made it a winter project redoing this truck. Good luck.