Fix It

Explore » home» a » fix » frame » how » of » out » rust » to » toyota » How to Fix Rust Out of a Toyota Frame

---

How to Fix Rust Out of a Toyota Frame

Depending on the climate where it is driven, your Toyotas frame may have rust damage. If caught early enough, preventative measures can slow the rusts progress and delay the need for extensive repairs. If the rust damage is significant, it can lead to failures in suspension and steering components, causing the vehicle to be unsafe. It is critical to inspect the frame carefully to determine the extent of repairs needed. This typically requires old sections of the frame to be reinforced with new pieces of metal. If the amount of rust damage is severe, the best choice may be to completely replace the section of frame, taking care to reinforce the joint. If you are not comfortable using a MIG welder, this repair is best left to a professional. But if you have the necessary skill and safety equipment for MIG welding, you can accomplish the job.

Instructions

Remove Old Rust

1

Spread the naval jelly on any rusted parts of the frame. Wait 5 to 10 minutes. Rinse with fresh water. Take care not to let the naval jelly remain on painted surfaces as it will remove the paint.

2

Assess the severity of the damage. Coat the area in rust-inhibiting paint if the rust has not gone completely through the frame metal and is not at any bolts or welded joints on the frame.

3

Check the repair regularly. This process may need to be repeated periodically to prevent the rust from returning or spreading.

Welding Reinforcements

4

Determine the appropriate repair --- welding a piece of angle bar to the existing frame metal or cutting the frame metal and replacing it completely. If the frame is compromised in many locations, replacing the entire section is likely preferable. Frame sections can be sourced from a Toyota dealership, or an auto dismantler may be able to locate a used one in good condition for less cost. Alternatively, hire a professional welder to fabricate a new frame section using the old one as a template if the vehicle sees heavy use, such as pickup truck.

5

Measure the section of frame to be reinforced and use the grinder to cut a length of angle bar. Add 3 to 4 inches on either side of the bar to overlap the frame. For example, if a 2-inch section of frame has rusted through, the reinforcement should be 8 to 12 inches long. Features of the frame may dictate variations to this, but it is better to overlap as much undamaged metal as possible.

6

Clamp the section of angle bar to the frame where it will be welded and mark any bolt holes or other features. If the reinforcement is in the area of a welded seam, it may be necessary to cut off the welded metal (such as a shackle) and reweld it to the reinforcement. Measure the location of the component carefully to ensure it goes back in the same place. It may also be necessary to trim the reinforcement to fit around features of the frame that to not need reinforcement.

7

Remove the clamps and drill the necessary holes in the reinforcement angle bar. Use the grinder to trim off any metal necessary for a good fit. Test-fit the reinforcement again to ensure the holes are placed properly and the piece fits flush against the existing metal frame. Use the wire brush wheel on the grinder to clean up the metal surface on the frame in preparation for welding.

8

Weld the reinforcement in place using the MIG welder. Reweld any other components such as suspension shackles. Paint the repaired area with rust-inhibiting paint and follow the above directions for periodically inspecting and refreshing the paint. Repeat this process for any other areas that need repair.