How much rust is too much?

[vol4runner]

My 96 has some rust on the frame, hitch and some other spots underneath. (Not a surprise for these from what I've heard.) The back end is worse than the front. The steel seems to still be solid...no holes yet. I'm wondering how much rust damage is too much to try to repair and/or clean and recoat. I really like my rig and want to keep it for a while so I'd like to help keep the rust from getting worse. What are the best methods of cleaning it all up? Any thoughts from you guys?

 

[Mr. Leary]

:worthless


A method I have used:

Thoroughly clean all areas to be worked on...

Sand down rust spots thoroughly with wire brush, sand paper, or pad.

Clean off residue with brake cleaner and allow to ventilate.

Apply Muratic acid to the rust areas to chemically neutralize the rust.

Clean again with brake cleaner and allow to air dry.

Use Rust converter primer... one good coat should do the trick.

Apply rubberized undercoat (there are several options here) over primer.


Repeat process for EVERY instance of rust that you discover, and investigate the hard to see areas with a mechanics mirror.

After this you should be in good shape, at least as long as the rust has not structurally compromised the vehicle.

Post up pics and I can be of more help....

 

[98_4runnerSR5]

:worthless

Need some pics to show how much rust were talking?

 

[rjaudi]

Yes we need pictures of some various areas of the undercarriage. Mine has a large amount of surface rust, but doesnt seem structural. I have replaced the rear coolant lines, threw away the hitch and needed a new muffler though. I have seen some frames eaten through so we do need pics to see how bad we are talking.

 

[vol4runner]

Thanks guys for your help. I'll take some pics tomorrow after work and post 'em up so check back.

 

[vol4runner]

Sorry it took me a few days to get some pics posted, but here ya go. This is what the rear of my runner looks like underneath. No holes in anything that I could see. What do you think? Difficult to repair?

IMG_0049 on Flickr - Photo Sharing!
IMG_0048 on Flickr - Photo Sharing!
IMG_0050 on Flickr - Photo Sharing!
IMG_0052 on Flickr - Photo Sharing!

Thanks for your help.

 

[rjaudi]

That is not bad at all. It's up to you if you want to try to coat some of it with rust encapsulator like por15. It looks like you dont have a fuel tank skid.

 

[WrexHAmm]

That's nothing! I ran a 96 Tacoma with way worse than that when I lived in Iowa. Rust happens.... IMO the best thing to do it get some wire brushes and sand it off. They shoot some paint or something to delay the rust. I would be more worried about the upkeep of the other cars parts before the rust. Just don't let it turn to body rust.

 

[vol4runner]

I've been taking care of other maintenance and parts issues as necessary. The previous owner kept up with all the maintenance so that made my life a little easier.

I may at least take care of the trailer hitch first 'cause it looks pretty bad. Then i'll crawl under there before winter and get a jump on the rest of it. Glad to hear that it doesn't look that bad.

I'm familiar with POR 15 but haven't used it. Is it worth the money?

 

[JohnsD90]

I'm familiar with POR 15 but haven't used it. Is it worth the money?

It is worth it.

 

[Reina]

My 4Runner look close to that when I first got it.
Just like my 4Runner it looks to be surface rust only.
You could just do what I did.
I just used a sander and did a number on the whole under body then spray painted it with so call rust preventing paint. It took about 2-3hr.
It has been a year since then and it is still holding up ok ^_^