Frame Rusted Through, Whats my Next Move...?

[tvpierce]

I could re-weld it when it warms up and then go the POR 15 route, the only issue with that is that first i would want a better welder than my 110v Hobart, which would be a couple hundred at least. Plus the cost of a gallon of POR 15 (i think runs like $150 or so) and now I'm into it about $800 ish depending on how much I spend for the welder. Don't get me wrong, I'm all for excuses to buy new tools and work on new skills...

I've gotten an offer for a pristine frame for $500, but its 14 hours away... plus the time required for the swap..

So it sounds like here is what i'm down to:
1. Buy frame and DIY swap it (long project time, low-med cost, excellent results)
2. Weld some more on the frame (low project time, low-med cost, mediocore results at best)
3. Buy another 3rd gen (no project time, high cost, mystery results)
4. Get out of 3rd Gen 4runners and into something else, pickup (like a chevy), tacoma (higher cost), or beater daily driver like a civic or corolla (100 mile daily commute).

Which option would any of you realistically go for?

I'm just looking for other opinions at this point to try and separate as much bias and pride I have wrapped into this thing.

thanks again for all of your replies

The frame is only 1/8" steel. A 110v MIG should handle that easily.

 

[Scramble]

Not bad. Now that you have another daily I wouldn't even be in a rush. A tiny hole like that isn't anything dangerous to drive on yet though. Start fluid filming those body crevices though, I see plenty of rust beginning on those areas. And definitely not as easy to repair nicely compared to a frame.

Yea, I could still drive it but it got so cold out I couldn't finish the brake shoes or put the rear bumper back on. Plus after all of the sanding & painting I did I dont want to take it out in the salt anymore. At least until I'm done with the rust repairs & spay a protectant over the entire undercarriage.
I found a set of used for 1 season Blizzaks on CL for $200 & my FWD car is doing great in the snow. Today I'm getting plates for the new 4R & picking it up from CT on Sunday.

 

[T4R2014]

Yea, I could still drive it but it got so cold out I couldn't finish the brake shoes or put the rear bumper back on. Plus after all of the sanding & painting I did I dont want to take it out in the salt anymore. At least until I'm done with the rust repairs & spay a protectant over the entire undercarriage.
I found a set of used for 1 season Blizzaks on CL for $200 & my FWD car is doing great in the snow. Today I'm getting plates for the new 4R & picking it up from CT on Sunday.

I hear you. The snow is fun to play in when it's coming down but the salty mess afterwards is just awful. At least they aren't using brine like back in 13-14.

 

[pablopakman]

OP,

Yeah, your frame is pretty toasted. There isn't much "good" frame left so at this point if you want to keep the truck, I would swap a better frame into it. I am surprised it passed inspection honestly....

I like the idea of buying a decent beater for your long commute while you do the frame swap.

I remember when I first got my 97 and posted pictures on here of the frame. The amount of hysteria over the handful of surface rust areas was unreal. When I see pictures of frame rot like yours, it makes me sleep better at night because mine is no where near that bad. In fact, I don't have a single hole or weak spot anywhere, it just had a bunch of surface rust which is now gone. And yes, I inspected the inside of the frame and it's solid.

One last thing, I prefer LPS 3 for a rust preventative FWIW.

Yeah i'm seeing some decent beaters I like on craigslist so i'll probably get the tax return and then go that route. It was definetely a backwoods shop and the guy was doing me a solid by passing it to give me time for the rest of the year.

I'll check into some LPS 3 for future use.

 

[pablopakman]

The frame is only 1/8" steel. A 110v MIG should handle that easily.

Thats kind of what i was thinking so poor quality of the welds probably had more to do with the winds on the sheilding gas and the 20 degree temps.

 

[thecole1098]

I feel so bad for yall that live in areas exposed to salted roads. I couldn't imagine having to deal with this kind of stress on my rig. Best of luck to the OP.

 

[habskater11]

There is no VIN on the frame, surprisingly enough. Just the frame number, which is a glorified model code, not a serial. Not an issue.

Don't tell me it's hidden. I wire-wheeled and POR-15'd every square inch of that frame. NO VIN on old one or new one.

Also, no difference between 5-speed frames and autos. I put an auto on my 5-speed. Only 2WD and 4wd and I think 4-cyl and 6-cyl.

Also, the variations in body mounts by year are no sweat, if you have the mount hardware from the original. The frame itself does not change. They just redesigned the mount hardware. I put an '02 on my 1999.

What about all the Tacoma’s that have new frames? It’s not an issue. Vin’s can be found on doors people replace them. Not an issue.

 

[phattyduck]

What about all the Tacoma’s that have new frames? It’s not an issue. Vin’s can be found on doors people replace them. Not an issue.

I was thinking the same thing - along with the rear hatch, hood, fenders, etc. I can't see how replacing a frame would be an issue for a safety inspection.

-Charlie

 

[Mark_BC]

I feel so bad for yall that live in areas exposed to salted roads. I couldn't imagine having to deal with this kind of stress on my rig. Best of luck to the OP.

I just don't drive it in the salt. Yesterday I drove up the Oregon coast because I was hoping to avoid salt on the I5. Turns out the coast gets salt spray, whoodathunk?? That mixed with the rain gave it a good salt bath. I drove through a good rainstorm in Portland which probably washed most of it off but today I took the hose to it everywhere. But that won't be good enough to get it all from every nook and cranny. Tomorrow there will be lots of rain here so I'll take it out on the freeway for 10 minutes, that will get rid of it all. Luckily I've already painted inside most of my frame, it's in great shape. But there are still some unprotected underside components which will have to wait until next summer to get cleaned and painted.

While in Portland I looked at an 86 Troopy Landcruiser from Europe. Yikes, talk about frame rot from Ziebart or whatever it is they put on it back then which just trapped the salt. And the frame was full of sand so I couldn't tell how far the frame was rusted. I think I'll stay away from that one.

 

[ChrisRunner1]

Hi... I have a 02 limited 4Runner 4WD and the frame is rusted out - I have a clean frame to swap... looking for some that has experience without the dealer price. Any help?

 

[Malcolm99]

Are you asking for someone to do the work or instructions?, maybe mention location and someone might be able to help or direct you to help.

Just to clarify, On the passenger side frame rail behind the front tire there is most defiantly a chassi Model - VIN on all 3 of my 4R's. It says VZN185-902XXXX on my 99' and similar on the 97's I own, every 4Runner should have this, or atleast the model number on replacement frames.

 

[spartacus]

Hi... I have a 02 limited 4Runner 4WD and the frame is rusted out - I have a clean frame to swap... looking for some that has experience without the dealer price. Any help?

If you need help look at community garages or motor clubs in your area. Few have done it and have useful threads.
[MENTION=168172]sleepydad[/MENTION]
1997 Sketchy SleepyDad build
[MENTION=10169]TheDurk[/MENTION] is one of the early ones.
Frame Rot!! Is this the end? - Toyota 4Runner Forum - Largest 4Runner Forum
[MENTION=317458]Venka93[/MENTION]
Frame Rot!! Is this the end? - Toyota 4Runner Forum - Largest 4Runner Forum

 

[Boognish_Forever]

Lots of 4Runner frames are going to be beat up with salt from the snowstorms around America right now. I wish I treated my frame before the snowstorms happened but I just didn't have enough time. I see my frame to last another 4 years or so.

Fortunately the west coast hardly uses any salt when it snows. But the chains and studs people put on there vehicles sure chew up the roads. That’s why you gotta have 4wd or awd in the mountains or you are getting nowhere.

 

[2001 Limited 285K]

I didn't see SafeTCap mentioned but I've had a good experience with mine to fix frame rot on the rear passenger side near the muffler that caused a failed safety inspection. Cost me about $220 for the part and about $900 for the install. Link here: 4-Runner 1996-2002 3rd Gen Archives - autorust.com

 

[Running4TheRunner]

I live in NNJ by mountain creek off rt 287. I have a 3rd gen that was rear ended, but the frame is straight no rust. Let me know if you want a price on it. I'm still picking a few parts off it but when I'm done we could make something happen potentially. Send me a message

Do you still have that frame ?