My current frame is rotten, I should have taken a screwdriver and poked the frame then I would have known about the large holes. Instead of whipping the PO I will just deal with it. I found a great 2001 frame, am I insane to think that’s a better route than my plasma cutter and welder? I have plenty of steel. 400$ for the frame?

 

A good clean frame will probably be easier and less hassle in the long run

 

That’s what I thought, I’m not in a huge hurry. I’m rebuilding the 4.0 into a 4.6 and I want to do it all right. Thank you for your reply

 

I would absolutely do the frame swap. To do the welding/patching throughly you’d need to remove the body anyways. The time you’ll spend replacing the frame wouldn’t come close to the time it’ll take to patch it up. And In the end... you end up with a complete solid truck instead of a patchwork of repairs.

 

If you don't have access to a lift, it will be easier while the engine is out too, just remove the transmission, that way you don't have to raise the body as high to roll the frame out.
My 04 has 1 rotted out spot behind the passenger rear axle. So, at some point, I'll have to fix that it in order to get it to pass Va state inspection, and be road legal again.
If you do swap frame's, please post pictures and pointers on the forum.

 

The PO did not replace u joints in the front drive shaft so it came loose and hole in trans cover. I have one so the engine and transmission were coming out the make the 4.0 a 4.6 and replace the transmission and reseal it all. Should I sand blast the new frame then prime and paint? What should I use to seal the frame?

 

30 years ago I pulled the frame from an fj40 and had it acid dipped. It cleaned every speck of rust off of it and I saved the work of blasting. Just an option.

 

You could have it powder coated.
Or, there's a brush on black coating, begins with a P, seals in everything, stops rust completely.
I can't think of it's name, but it works excellent, I'll find it and come back.

 

Pors 15

 

I would go acid dip with powder coat, that way you get the inside too if they used the charged powder.