I have a bit of an issue on the passenger side rear - it is still solid but I figure get sorted while the metal is still good. My plan is to basically add a "C-channel" around the iffy bit and get it welded in place.

 

I should have noted any suggestions or recommendations

 

did you check the inside between the fuel tank, as that is a major spot for rust, not just the bottom,

 

@frostythor I did check the inside beside the gas tank both sides, the right side has a small bubble maybe 2 inches by 1. I may have to stabilize for the winter and address in the spring as it will be a tank drop to fix correctly.

 

Well this got more interesting looks like a PO whacked the frame rail good and put epoxy putty in the crack then covered with a big coat of under coat rather than fixing it right.

Looks worse than it is both rust patches are about 6 inches long, not any depth to side one but the lower is a mess. Using hammer and screwdriver I found no other obvious weak spots.

My plan is to try and get it fixed without dropping the gas tank, as I can not weld so that is pay for someone to drop the tank and put it back. The lower crack can have a patch welded over, although a u shape going all the way up the sides would be ideal a patch along the bottom would suffice. I still need to do more clean up to get to bare metal to find a solid anchor for the patch.

 

Mine was a bit more than that, so I ended up replacing the back section, the worse bit was getting all the fuel out of a full tank, but it is the best way to do the job

 

@frostythor I agree, with replacing the rear but it is only the passenger side and cost will be pretty high I suspect. A 1/4 frame will run me about 900 CDN shipped and 1/2 frame about 2000 shipped.

Labor is an unknown until I make some calls.

Getting a patch or the frame repair panels is more cost effective - depending on the rust of course.
The big issue is dropping the tank something I can do but some shops won't.

 

Keep us posted please! I know this is going to be an issue for me as well. Looking forward to reading how you overcome the various challenges.

 

Well had 2 shops take a look both indicated it is not "yet" a safety issue but needs to be fixed.

Labour 1500 - 2000 CDN plus parts - them dropping the tank.

The question is how far the rust is, an initial inspection hammer and drift seems to indicate it may be solid up to the shock and spring towers. I am not an expert but it did not deform, so a my choices are a quarter chassis or repair panels.
I am leaning towards the repairs panels :

These 2 products :

For the sides - this kit removes the requirement to remove and reweld all the mounts but lacks the lower metal


And this one for the lower which I also need.

https://froggatts.co.uk/product/chas...2-and-classic/

Total cost is about 200.00 CDN for the parts.

A 1/4 frame is 1200.00 CDN Shipped to my door and the same labor.

At this point I will need to borescope the frame and see how bad it is but the wrap method will give the truck a few more years.

At nearly 20 years old there are a few considerations on how much to throw at for sure

 

Further update on the recommendation of a UK Rover owner I whacked around with a framing hammer and nail set looking for soft spots none found. Even the bad section only dimpled in a very minor way
I then got a borescope and inspected the inside - good news other than a ton of spider webs no rust flakes lying in the bottom even when I struck the frame with a hammer and punch in the area around the scope.
The damage appears to isolated to the section in the images and only on that one side which is good.

Based on that I will most likely go with the patch kits as the frame appears to be largely intact and they will add full length additional structure.

I will keep this updated as I still need to find a mobile welder who will take it on.