Quote:
Originally Posted by DontRoastMePlease
Hey y’all, I’ve been doing a bunch of research but can’t find a good estimate.
I’ve got a 99 4Runner with SEVERE undercarriage rust. Just curious about how much it would cost to get a whole new undercarriage and frame.
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Things needed before I could answer:
1. Post photos please. Lots of them.
2. Is the truck in otherwise excellent mechanical condition?
3. How much work would you do yourself?
4. Do you have the space and a lift?
5. Can you weld? Bend a frame? Sandblast? etc
6. Do you have other reliable transportation while the 4Runner is up on a lift (or jack stands)? It could take a long time since it's both a ton of work and you'll likely get delayed due to supply chain disruptions when ordering parts you didn't know you needed until you starting taking things apart. This is true even if you're paying someone to do all the work. If the truck is all torn apart, and a critical component is simply not in stock, you'll have to wait it out.
7. What's your goal for this project? That will partially determine how much you may spend. Eg, daily driver to get to/from an office? Off-road toy? Farm truck?
8. How much are you willing to spend on this truck before you'd wish you had just bought another vehicle?
9. Does the truck have sentimental value? Or is this strictly a cost/benefit analysis?
Almost done with my frame swap.
Here are some lessons learned:
1. You'll need to source a clean donor frame yourself. Make sure you get the VIN of the frame and do all your homework on the frame and your truck to ensure they'll be fully compatible before you buy. Sometimes the sellers think it's a 2000 frame, but the VIN (and the position #2 body mounts) prove it's a 1999. That stuff matters during a swap.
2. You'll need to manage the transportation of that frame. Just because the seller ships it doesn't mean that it will arrive. Ever. You might have to end up renting a trailer and getting several friends to help take care of the "last mile."
3. You'll likely need to spend a great deal of time prepping the donor frame (even if it's advertised as "rust free", it's still about the same age as your truck, and will need some work, even if it's just sanding, cleaning, painting.)
4. If you're really rusty, expect basically every single fastener to break or need to be cut off and replaced.
5. Expect basically every bushing and suspension component to be at least partially damaged. (Be pleasantly surprised at whatever can be cleaned up and reused).
6. The body work on the undercarriage is not to be underestimated if you really plan on getting everything rust free and more or less rust "proof".
After my experience, I believe a frame swap is only worth it if:
1. You got the truck for very, very cheap AND it's in excellent mechanical condition, or
2. You can do all the work yourself AND you're very bored and looking for a new hobby, or
3. You have plenty of extra money AND the truck has a lot of sentimental value to you.
As far as costs go, your location/region will tremendously affect the quotes you get from mechanics. It's a ton of work, and the overall cost is incredibly variable given there's no good way to know how many parts will need to be replaced. If outsourcing, look for a mechanic pretty far outside of major metro areas who's done frame swaps before, who's willing to let you buy your own parts, and willing to let you do some of the work yourself in their shop.
PM me if you want to get into the numbers. So much depends on your answers to the above.
You very well might be better off looking for a different vehicle.