Rusty Frame

Hi, I have a 04 xtracab with a pretty rusty frame. I was wondering what peoples thoughts on it were? I would love to keep the truck forever, but the ride is getting pretty rough on the original suspension. I wanted to put new shocks and springs on it but my mechanic told me he would not put anymore money into it because of the frame rust. When I bought the truck in 2016 the frame had not been warrantied so its the original, but the dealership did put a undercoating on it which is now flaking away as you can see in the pictures. I already had to have one crack in the frame welded on the driver's side were the front of the leaf spring attaches to the frame, and found another little hole in the frame near there which you can see in the first four pics. I took a scotch brite wheel and ground off some of the rust to check out the metal underneath and it didn't seem too bad. Would it be a reasonable thing to try to grind all the rust off the whole frame and coat it? Or is that a waste of time on something so rusty, especially when I cant really tell what type of shape the inside of the frame is in?

 

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https://www.tacomaworld.com/threads/rust-prevention-treatment-consolidation-thread.355928/

 

It's likely 10x worse on the inside where it can't dry out. That's the big issue with those frames that are that far gone. It's not so much what you see on the outside but what you can't see on the inside. It's a shame that this is a thing.

 

If you are just using if for street driving, my opinion, it will last a while yet. For sure it's no cherry. Will it need additional minor frame repairs for cracks, definite possibility. 3-5 Winters if you address it now.

I'd definitely use some rust reformer, then the coating of your choice (Fluid Film, Woolwax, etc) inside and out.

Without seeing the rest of the truck it's hard to give you advice about putting money in it for suspension upgrades vs driving it until the frame needs replacement.

 

The hole in the frame (“perforation”) would have qualified it for replacement if Toyota had discovered it 2 or 3 years ago. Many rust belt mechanics would be reluctant to put that thing on a lift in the first place, let alone get under it.

 

Here is the thing if you have a friend or several that can do the needed welding and fabrication for consumables and needed materials it is feasible .

Having that done paying the going labor rate to have it fixed correct could be an easy $2000.00 to$ 3000.00 plus the added cost of brake and fuel lines and other hardware .

Only you OP can decide !

 

I would get a remote camera and inspect the interior of the frame. As they say "rust works from the inside" Take a close look at what you are facing. If you think that the frame is going to be around the get a 4.5 inch grinder and wire wheel what you can and use POR15 to cover it. POR15 is some of the best on the market. Do remember that you might only extend some extra time.

 

Your frame resembles puffed pastry dough.

Your mechanic is right, I wouldn't want to do any more work on it (before fixing the frame) either.

It's possible to "fix" this, but don't kid yourself, it'll be a big undertaking. Your best bet, honestly, is a frame swap, which is a huge undertaking in itself, but you're better off starting from scratch than welding a bunch of bandaids to this one.

The other thing is that the frame clearly isn't the only thing that's rusty. All the bolts, hardware, brackets, etc... are all going to be rusty too. Probably just getting the shock bolts off will take all day.

So if you have some attachment to the truck, you can definitely make this like new(ish) again, but it's going to take time and money. So I'd get yourself another mode of transportation in the mean time...