I'm hoping someone can help me find a solution to the frame on my '03 V8.
Some backstory: For all practical purposes, this is my "pet project" vehicle. I have replaced and upgraded many parts (engine components, new fluid lines, suspension upgrade, etc), all in my garage. I have no intention of ever selling the truck, as I have a lot of time and money invested in keeping it running as long as possible.
With it being an older vehicle in Wisconsin, there is surface rust present, but the frame overall is solid.
The issue is with one section of the frame, located behind the passenger side wheel well. Here's two images (one top-down and one underside) of the affected area:
IMG_20200928_224458055.jpg - Google Drive
IMG_20200928_224511898.jpg - Google Drive
What appears to have happened is a condensation line had been incorrectly routed to where there was a constant source of moisture on that segment of the frame, leading to it rusting through. I will re-route the line and I had intentions of cleaning and coating the underside of the whole truck myself to halt rust development, but after the extent of the damage became apparent (this past winter) I have put the project on hold as I explore options. I'd like to get the frame solid and then I'll seal it to stave off an entire frame swap.
I'm wondering if the Safe T Cap I purchased from autorust.com will be able to be installed and give more structural integrity to the truck's frame. Here is the product I have:
Front Frame Section, V-8 Model (ART-200-R) Passenger side - autorust.com
I will eventually want to do a frame swap, but this is not in the cards for me at the moment- Right now I just want to improve the safety of the truck, and I would be very thankful for ya'lls opinion and expertise. If the cap and a patch or two isn't viable, is there a possibility of replacing the whole section? I'm not a welder, and this would be the first work I've really gone to a shop for my truck, so I greatly appreciate any help on this.
Really putting out the Bat-signal here. If anyone has suggestions to a shop, I'm all ears. I have a few days of work I need to take off before the New Year and am willing to travel to get this taken care of properly by a professional that won't talk down to me or shy away from the job. I'm in south-central Wisconsin.
Thanks! Ya'll rock!