Rusty Runner Repair

[Runnergade]

Michigan, salt, and Toyota's rear axle/frame are all unforgiving mistresses when it comes to rust. So I've decided not to procrastinate any longer and get started on this rust job while I have time and the weather is right. I've been thinking about it since I got the truck in January. I knew what to look for and I didn't feel the rust was enough to turn me away. I had a shop confirm that the frame and axle are still solid. The previous owner did a great job of taking care of her, but I'm still concerned and a bit more committed!

So here's what I'm working on. What you're looking at though, is an after picture when a lot of the top layer had been wire wheeled and beat with the needle scaler, so it might look worse. There was a lot more black scale on the hitch and axle. There are no photos of the frame but I will be spraying that down with converter and then FF. I would like to get the inside of the frame with some used oil that I have lying around so if anyone can give me tips on how to inject it that would be great!!

<img src="http://i.imgur.com/gB1kDtg.jpg" title="Hosted by imgur.com"/ width="530" legth="354">
<img src="http://i.imgur.com/p698jq0.jpg" title="Hosted by imgur.com"/ width="622" length="415">

Below is a photo of some of the tools to help me get this job done.
<img src="http://i.imgur.com/HaAWWSA.jpg" title="Hosted by imgur.com" width="622" length="415"/>

Thought I would give you a rundown on what's what, from where, and how much.

PREP WORK
21 Gal Air Compressor (B-day gift from wifey) - Harbor Freight - $170
Mini Air Needle Scaler - Harbor Freight - $30.00
Reversible Air Drill - Harbor Freight - $17.00
6pc Wire Wheels/Cup - Harbor Freight - $4.00
6pc Detail Wire Brushes - Harbor Freight - $2.00

RUST CONVERSION
Corroseal Rust Converting Metal Primer - Home Depot (Online) - $54.00
Spray Bottles x2 - Dollar Tree - $2.00
Paint Brushes - Dollar Tree - $1.00

I chose Corroseal because it had great reviews, including one from a rusty 4runner owner on HomeDepot.com and was cheaper than Eastwood. It converts the rust to magnetite.

TOP COAT
Rust-oleum High Performance Enamel x2 (not pictured) - Walmart - $10.00
I'm still debating on whether or not to use the rustoleum paint. I want it mostly for the color.

SEALER
1 Gal Fluid Film Rust & Corrosion Protection - Local Lawn Shop - $42.00
1 Bottle of Vegetable Oil (to thin fluid film, not pictured) - Dollar Tree - $1.00

I chose Fluid Film because it's been sworn by with great reviews, and recommended by a 4runner owner on YouTube, and would definitely aid in keeping the magnetite protected. Just converting won't keep your frame/axle protected.

ESTIMATED TOTAL: $333.00 OR $163.00 (if you already own a decent sized air compressor)

I haven't started the project so this estimate may rise as I tackle it this weekend and it may vary depending on how you choose to go about it.

Rust Conversion:
After the bottom was wired, sanded, and needle scaled I power washed underneath to remove any oils, dirt, and etc. I started with the hitch. I was happy to see it being converted to a black finish. The cheap spray bottle didn't spread out too well so I ended up using the brushes. Overall I'm happy. It'll have to cure for 24 hours so tomorrow I will be finishing up and putting the fluid film layer on.

<img src="http://i.imgur.com/boGmVtj.jpg" title="Hosted by imgur.com" width="622" length="415"/>
<img src="http://i.imgur.com/2B3skIW.jpg" title="Hosted by imgur.com" width="622" length="415"/>

 

[Jowenbrown]

Thanks for the informative post. One of the disadvantages of living three miles away from the Great SALT Lake is rust... everywhere.

 

[Run 4 Fun]

Thanks for the informative post. One of the disadvantages of living three miles away from the Great SALT Lake is rust... everywhere.

Or anywhere in Utah for that matter. The amount of salt they dump on the roads in the winter is crazy stupid. I can't tell if there is an inch of snow or a inch of salt on the roads. :driving:

 

[Runnergade]

Thanks for the informative post. One of the disadvantages of living three miles away from the Great SALT Lake is rust... everywhere.

I was out in Utah last summer checking out Bryce and Zion and I never thought for a second that snow, salt, or rust would be a problem for you guys. Learn something new everyday!

 

[Runnergade]

Any suggestions on what tool I can use to get oil inside the frame?

 

[Johnboy11]

You should really try POR 15 It suppose to work great, When I had a Jeep Wrangler people used it all the time with great success.

 

[lhsoulrebel]

If you haven't painted the frame yet, paint it with the por 15.... Its the only stuff that truly seals it... it adds an extra step because you then have to paint over that, but learn from my mistakes... 1 year and that rustoleom will start pealing off again... I did the exact same thing as you, and ended up having to do it again.... use the por15 if you never want to do it again!

 

[Jowenbrown]

I was out in Utah last summer checking out Bryce and Zion and I never thought for a second that snow, salt, or rust would be a problem for you guys. Learn something new everyday!

There's a reason the 2002 winter Olympics were here. Even Southern Utah gets a few feet of snow every year.

 

[meltdowner]

Corroseal, excellent.