I would not put a lot of money into it. If it was ME.

I'm stupider as they say. Going to toss a boatload at it but only on things I can relocate to a clean frame with 4.88 elocker when I find it....until then this is my learner, and I'm going to be an ace with the torch, new crap welder, cobalt bits and cutting wheels in no time the way its going.....

The frame is salvagable. You need to spend hours and hours (days) with a needle scaler stripping it down to get the rust scale off from it. Then it can be coated with POR-15 or your coating of choice. And will need annual treatment of Fluid Film or WD-40.

However, that body is gone... and you're not going to fix that with welder. I would seriously not put much time and effort into it.

In your original post in 2015, you could have saved it. IMHO, it's too far gone now.

i would sell it if i could, and spend the proceeds on a 4th gen (with a pre-purchase inspection). that rust is bad, with so many future issues awaiting.

Nothing wrong with gaining vaulable skills. You be able to weld decently upside down when your done it's a plus. Plus gain all kinds of skills that can be used elsewhere.

The others are correct it's a pile of work and time. I just enjoy the transformation myself and the satisfaction I can do it.



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Just so I don’t look completely nuts I showed the worst of it above — this truck rusted in a strange pattern. Maybe because it sat idle for most of the time idk, but the usual problem spot — rear lca bracket I can bang with a hammer




Rocker area seems OK, I need to remove the trim to be sure:



transfer case fwd not as bad:



Two worst panel spots are right rear door, drives side foot

That rust looks pretty dry. What was your undercoating schedule and with what product?

That's not super rotted for the salt belt. I can so you alot worse then that from PO neglect. Would be good to clean it all seal it with something. Then get into a rust inhibitor plan.

Eventhough the frame is still intact and fairly strong it will have thin spots in it as they mostly rot from the inside out around here. So super cleaning and coating the inside of the frame will extend frame life..

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You also want to get s few something in your rockers so they dont rot out as well. Mostly go in the back inside and out and the front a few inches in on the outer rocker. You see those tar patches on the inside rocker. Pull those off and get the rust inhibitor of your choice in there then just snap a solid grommet in the hole its resealed up.

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I'm going your method -- I have some eastwood internal coating so will spray that but I'm going to blast anything internal with FF also

Your rig isn’t that much worse than mine. I’m in the Hudson Valley only 15 minutes from CT so similar road conditions.
I’ve paid close attention to Brillo’s thread on rust repair and some others on the forum who have been very encouraging.
Have spent endless hours with a wire wheel on my angle grinder and a compact needle scaler ($30 Harbor Freight). In the past few days I just completed stages 1 & 2 (degreaser & metal prep) using POR-15 products and am now ready to apply the chassis paint.
After removing all the flaking rust I was pleasantly surprised to find zero perforation, soft spots or areas of further concern.
Get yourself a compressor and needle scaler and go to town. It’s messy work but you’ll learn as you go and it’s good for the soul.
BTW......I think @Brillo 76 needs a new handle....Rust Doctor!
Keep the faith @brillo_76 you do good work and your contributions are very helpful!

Haha my needle scaler arrived today, my larger compressor will be here next week, wire wheel is coming out this weekend, and Brillo is the man! I'll document as I go....everyone loves pics

What were you doing the past 5 years? You had a lot more to work with 5 years ago. Totally honest but those control arm brackets look ready to snap off now. Had you just sprayed the hell out of it with used motor oil it would look very different. My opinion but the body mount and floor looks poor too. That will require a lot of patching.

So you decided to keep it from 5 years ago? That’s good that it lasted 5 more years. Mines not even a quarter as bad, gives me hope mine will last a long time.

I would have sold that thing and invested in something that requires less effort