So I'll add photos later but I've been back and forth on this for a while. I need to cut out the front foot of frame and weld in a donor piece I pulled from a junk truck. I'm hoping to get some tips and guidance since I'm not a professional welder and and want to make sure I don't burn my truck to the ground

I have a 94 4x4 manual T4R with the 22re. I absolutely love this truck and it really works great for the work and play that I do. I've spent months even years looking for another one with the same features and can't find one even on the west coast or Arizona, etc. (I live in Hawaii) It's all v6's and having driven the 3.0 I'm not impressed.

So when I got the truck I was pretty new to wrenching and missed an issue that could have been much much easier to fix then . The AC condenser was leaking. All I knew is that the AC was low, so I filled it, and was happy with having cold air. Well it didn't last long and I refilled again. I didn't locate the leak for quite a while, and definitely didn't connect the dots that the small rust on the front frame cross piece (under the radiator) was actually started from the leaking condenser. Well eventually I figured it out. After using leak dye I noticed the leak was right above where the rust was. So, had I the time, I would have fixed the condenser leak and cut out the rust. Well circumstance didn't allow. I had to leave the truck sitting for a few months and when I came back I was shocked at how quick the rust had spread. I've since replaced the condenser but now have a bigger problem.

Basically the refrigerant ate through the frame coating and opened it up to the corrosive salt air here. 95% of the frame and body on this truck is in great condition. Unfortunately though at this point the rust is creeping it's way back to the steering box mount points and I want to repair it before it makes my truck useless.

My plan is to jack it up on stands pull the front bumper and wheels and anything else in the way. Thoroughly clean the frame and make as clean a cut as possible and prep it for welding.

The donor piece will be cut and sandblasted and other than the last few inches which I'll tape off I'm wanting to have it powder coated. Then I'll bolt it up to the two body mounts in the front and clamp it together with the rest of the frame and start welding it up.

It looks like I'll have to move the steering box and the steering arm bracket out of the way, but hopefully won't have to pull the radiator.

So my main questions, and this is where the photos will come in, is where should I cut the frame and what do I need to do to prevent a fire? The truck does have a slight oil leak and I'm kinda wanting to wait to fix that until I know this all comes out well. Though I'm wondering if that's a fire hazard and worth just fixing. Or can I just clean it up real good before I start?

I'm trying to decide if I should cut the frame behind the front most steering box and bracket bolt holes. If I do this there's still two big bolts each side holding them to the frame. The third bolt would go through the new piece of frame which I'm thinking will make the whole thing stronger. I don't plan to do any real pulling with the truck from the front and don't wheel it hard so I think it'll be pretty strong, but I'll likely add a piece or two of flat bar on top and bottom of each side to brace it too.

I'm wondering if doing it this way is going to be ok? Or would it be better to cut it in front of the front most bolt and weld it up there. This seems like it isn't going to be as strong as having a basically bolted on bracket as well as the welds, but I'm wondering if those steering box and arm brackets could put too much force on the welds?

I know this might sound like a crazy project to some, but I'm pretty excited to save this truck. To others it might sound easy peazy ;)

I could pay someone $500 to do it, but I would prefer to take my time and do it my self. Money's tight and while I'd like to upgrade the market is ridiculous especially in Hawaii. I'm also having trouble finding a vehicle that checks all the boxes like this one does. 3rd gens don't have the tail gate which I use regularly. and Tacos even with a cap can't fit as much stuff in a lockable protected area at this truck can. I can haul quite a bit of plywood, and lumber. Fit two 10foot longboard surfboards inside and lock it. Load it to the roof with all kind of tools, totes and materials. I even haul my ten foot Jon boat with 8hp Honda because that extra tailgate balances the load.

I'm working on photos now ;)