Rusted Frame - As usual - opinions please
 

Ok, before I can start upgrading my truck I have to address this rusty frame situation before the truck breaks in half.

I have searched and read many many previous posts over the last couple of weeks. I think I know what direction to take but still a little cloudy on exactly how to make it as good as I can.

Based on what I have seen from other guys on here my plan is to cut out the rotten section on the inside of the frame down to the seam, since it has rusted to that point and is coming apart at the seam. Cut out the bottom section where it is rusted out. Weld in new piece of angle inside the frame to form the new bottom section. Weld in new inside portion of frame. Weld in new bottom section at bottom of new angle. Then add reinforcing plates across all the new welded butt joints side and bottom. And weld the crack on outside of frame, and add reinforcing plate over weld.

My primary question outside of any opinions you guys may have is this; If I cut the inside portion down to the seam, how do I make up for the thickness difference? Do I just use a thick enough plate to come out flush with the adjacent box of the frame, or do need to get some kind of rolled metal to match how the frame was made in the first place?

Also, do I need to take the springs off to relieve the pressure on the frame before I cut those sections out?

Any opionions/help much appreciated. Would like to get past this so I can start on getting a locker and doubling my transfer case to make this thing do better on the trail. Thanks in advance for your help. Much appreciated. Jason.

[IMG]http://img.photobucket.com/albums/v2.../Frame-001.jpg[/IMG][IMG]http://img.photobucket.com/albums/v2.../Frame-002.jpghttp://img.photobucket.com/albums/v2.../Frame-006.jpg[/IMG]
[IMG]http://img.photobucket.com/albums/v2.../Frame-005.jpg[/IMG]

And passenger side pics. Not as bad, but plan to cut out same area since metal is very thin where it has been rusting much like the drivers side.
[IMG]http://img.photobucket.com/albums/v2.../Frame-003.jpg[/IMG]
http://img.photobucket.com/albums/v2.../Frame-004.jpg

Before you start you need to do the screw driver test over the whole length of the frame. Make sure there are no more bad spots.

I myself have patched many a frame on these trucks or rebuilt

Getting the old under coating off and getting it clean are the hardest part.

Just curious, what year is your truck?

Oh, yeah, It is a 82 SR5 long bed 4X4.

I did check the rest of the frame with a hammer and screwdriver. The only other spot that is a little rusted is up at the front hump in the frame, there is a seam that apears a little bit breached, but it is still solid there. Once I get it cleaned out it should be fine for a long long time.

Ok, got er all stitched up and painted. Now just to find some suckers to come help me lift the bed back on. [IMG]http://img.photobucket.com/albums/v2.../Frame-008.jpg[/IMG]

[IMG]http://img.photobucket.com/albums/v2.../Frame-009.jpg[/IMG]