Rust repair project (and a buch of other stuff)- my build thread?

Greetings,

EDIT: Adding table of contents

Is this a build thread? I'm going to start posting the progress of the frame rust repair project on my new-to-me Tacoma. Its a 2003 2.7L 4x4 M/T with over 246k miles. This forum has proved invaluable to me as a new Tacoma owner and given me the confidence I needed to take on this project. Thanks to all you great contributors.

The rear frame of this truck is wasted with rust and jerry rigged to stay together in a less than safe manner. The rear shocks are actually bolted to the bottom of the bed because the original mounting studs are rusted off. The rails over the rear axle had previously been patched with scrap steel and the worst welds I've ever seen. I don't know how long ago it was done, but the repair patches and welds have also begun to rust through.

I was going to use safe-t-caps to fix the problems, but instead got a pair of rust-free replacement rails from another TW member @Tour991, and I will graft them in to the existing frame behind the transmission cross member. The front half is also rusty but the structural integrity isn't compromised like the rear is.

Thanks also to @DBowers01 and his rust repair thread for inspiration. https://www.tacomaworld.com/threads/1997-frame-rehab-thread.550329/

Table of Contents:

Donor Frame
Post 38

Disassembly
Post 74
Post 81
Post 86
Post 88
Post 90
Post 102
Post 103

Frame grafting
Post 106

Reassembly
Post 112
Post 139
Post 140 new fuel tank
Post 143 rear small parts and brake lines

Trim Paint
Post 111

Frame Paint
Post 121

Clutch/Transmission
Post 112 Shifter removal
Post 117 Transmission removed
Post 118 Clutch/Flywheel removal
Post 126 Pilot bearing removal
Post 127 Installed pilot bearing / flywheel / clutch / pressure plate / clutch master cylinder
Post 128 Release bearing and clutch fork
Post 129 Clutch reinstalled

U-Joints / Driveshafts / Carrier Bearing
Post 132
Post 139

Here's a pic of the truck and a rust-porn teaser.
More to follow.




Just look at this....

 

Here's some pics of the frame rails with old repairs. Some of those welds aren't even holding anymore (if they ever did)

 

Here's some more rust, cross members are shot. I'm replacing all three rear cross-members and the bumper too which is also rusted out. Spare tire and gas tank cross-members are ordered, pending shipment from ToyotaPartsDeal. The center bearing cross-member isn't really all that bad but I figured I'd replace it anyway. Not available from Toyota sites, but just processed an order for a replacement from Amayama in Japan. Hopefully they come through.

 

Its beautiful.

 

Glad I could help. Keep posting pics of your progress.

 

wow.. lol.. Good luck, sir! here's another thread you may be interested in.

https://www.tacomaworld.com/threads/1995-rebuild.404579/#post-11304137

 

I'm still in awe of the shock relocation mount.

 

damn hope this thing was free / very cheap

will be nice when you are done with it. good luck!

 

Guessing that truck spent some time in the Northeast or Midwest to have that kinda rust?

 

Thanks, that was a good rebuild.

 

In this market? LOL. I had three criteria for my purchase:

1. 1st Gen Taco
2. Runs and drives
3. A/C works
4. Fit my budget
5. Actually be on the market

Ok that was 5 but it was the only one around for sale and it fit the bill. I took a gamble but I have no regerts.

 

Somewhere in upstate SC and/or NC. Don’t really know it’s history. It’s safe now in the no-snow zone.

 

South Carolina? That looks like something we drive around in Ohio. Was that truck driven on the beaches a lot or maybe it is a northern transplant. Those relocated shocks are really impressive. I'd like to see the genius that came up with that idea. I see a full frame replacement. My brother-in-law did that with his 93. He found a solid 85 frame and did it in his garage in a couple days.

 

Download the Toyota app on your phone. Add the truck to your garage and it will give you some good information on your truck.
This screenshot is my 97. Cool thing is it shows the day I bought it.

 

There was a old saying in the weld industry back in the day concerning weld integrity,,,, "welded at and missed,, shit at and hit", you have the latter

 

it’s gonna be a half frame replacement. That genius probably looked like this.

 

Haha i feel ya. as long as you are happy, you should have no regrets. personally, as a life long toyota truck owner in Ohio who has seen his fair share of rust - I find it is easier to get them running than it is to fix the rust in a permanent and respectable manner. i'd take a non running truck over a rust bucket. throwing in a used engine is a days work and pretty low cost on these things - rust repair is never ending.

i think you will do a great job fixing it up and have a nice truck in the end either way

 

It was a shoot now, ask questions later kinda thing. I didn’t know anything or what to do about it till after buying. I figured I’d figure it out. Most tacomas around here aren’t for sale, and if they are it’s because they’re wrecked.

 

i gotcha. its hard to find a clean 1st gen nowadays! you really need to jump on it like you did.

i will say the rear half of these trucks is usually what goes first, so you are probably covered if you fix the rear and then just maintain the front well (rust wise)

 

Thats a solid frame by Wisconsin standards. Saw a guy drive in an F150 drive past my house the other day and I could see right through his frame

Interested to see how you go about cleaning her up. Have you thought about getting a boroscope to inspect the insides? Hammer test most of these spots? I'm still trying to figure out what to do for rust prevention before this coming winter.

I feel ya on making the purchase. I was looking for a truck for months and found mine which had a replaced frame and had to jump (plenty of other problems) because I knew it would be a while before I saw another one without major rust. The outside of the truck looks really nice.