Frame rot

[dieselshadow]

Everyone has told me stitch welding was the best approach.

Correct, but you can finish all perimeter welding using the stitch method. That just means you are skipping around so you don't concentrate the heat in any one area. Stitching doesn’t mean you have to leave un-welded edges un-welded.

Finishing the perimeter by skipping around still allows for the heat not to be concentrated and allows you to have all the strength you can have as well as (hopefully) no more water/salt intrusion to cause more rust. There’s no benefit to not completely welding all the perimeters.

 

[brods]

One installed, one to be welded. More pics to follow later.

View attachment 122667

I hope that is not brake cleaner in the picture. NEVER use brake cleaner on parts to be welded. Welding them will produce toxic phosgene gas that can kill you!

 

[MarkEagleUSA]

I hope that is not brake cleaner in the picture. NEVER use brake cleaner on parts to be welded. Welding them will produce toxic phosgene gas that can kill you!

No brake cleaner. The frame was washed down with Simple Green and a scrub brush, then a flap disc used to remove the paint.

 

[brods]

Cool. I figured it was better to give you a heads up instead of just assuming you knew....

 

[MarkEagleUSA]

Actually, that is a can of brake cleaner in the pic (good eyes!). I used it to flush the hose for the frame spray. Not sure why it was under the truck in that pic...

 

[MarkEagleUSA]

Applied seam sealer to all joints prior to primer/paint.

I welded the piece next to the fuel tank (last pic) on the outside. Once I figure out a plan to drop the tank with rusted bolts I'll weld the inside. Didn't want to leave the frame open after cutting out the bad spots. At least now I can move it around in the yard.

 

[Ozymandias]

Looks serious now, good job.

 

[Bill Lins]

Not trolling but a serious question. Assuming that your frame rotted in that area due to trapped moisture, wouldn't leaving drain openings in the bottom of the patch help prevent a recurrence of the problem?

 

[MarkEagleUSA]

Not trolling but a serious question. Assuming that your frame rotted in that area due to trapped moisture, wouldn't leaving drain openings in the bottom of the patch help prevent a recurrence of the problem?

Yeah, I'm torn about that one. I can always put some in but for now I honestly dont know what to do.

I did coat the inside of the frame with Internal Frame Coating from Eadtwood. Supposed to encapsulate any existing rust and prevent more from forming.

I scraped out ad much loose stuff as I could get to. Made an L-hook about 18" long to reach into the rails. Got quite a pile of debris (pics to come) and a couple of surprises (pics to come).

 

[DavidC]

Maybe a 1/2 to 1" drain hole then spray it with the frame coating ?. I am not sure what that would harm structurally tho.

 

[MarkEagleUSA]

Maybe a 1/2 to 1" drain hole then spray it with the frame coating ?. I am not sure what that would harm structurally tho.

There are no weep holes from the factory. That makes the decision harder...

Plus, to be truly effective, I would need to find the low point (which shouldn't be difficult).

 

[Motorhead]

NICE Job Mike! I'd almost vote for a drain hole too. Out here in Commiefornia, a 2003 is relatively new and with only 165K on it, not even broke in. How's your OIL pan for rust?
I really don't think Dodge did that great of a job sealing and painting frame work and axles. My 2007 rear axle looks like it was dunked in salt water, let to rust some then half a$$ed painted. Looks bad and it has never seen a salted road. My body is rust free.

 

[MarkEagleUSA]

How's your OIL pan for rust?

Looks ok to me...

 

[MarkEagleUSA]

Painted...

 

[MarkEagleUSA]

And these were found inside the frame rails when I cut out the bad spots. Two on each side. They look like wheel studs but I can't figure out why they were inside the frame.

 

[MarkEagleUSA]

Here's some pics of the prep.

Bad stuff cut away.

Treated with Eastwood's Internal Frame Repair

The debris that came out of the rail.

 

[Wiredawg]

Super job and nice write up! Looks professional like them Joisey boys might do.

Cheers, Ron

 

[MarkEagleUSA]

Super job and nice write up! Looks professional like them Joisey boys might do.

Cheers, Ron

Thanks Ron! Hopefully it holds up. Doesn’t matter how it looks if it can’t do the job.

 

[mwilson]

Those studs are rib neck style. I installed my own fifth wheel rails and those hold the brackets.

You drill the holes in the frame and then using a supplied fish wire you send them in through existing holes in the frame and pull them thread end first out through the drilled holes for the bracket. The ribs bite into the frame when you tighten the nuts.
Your truck must have had a fifth wheel on it at some point??

 

[MarkEagleUSA]

Those studs are rib neck style. I installed my own fifth wheel rails and those hold the brackets.

You drill the holes in the frame and then using a supplied fish wire you send them in through existing holes in the frame and pull them thread end first out through the drilled holes for the bracket. The ribs bite into the frame when you tighten the nuts.
Your truck must have had a fifth wheel on it at some point??

I went out to look and found these holes just forward of the rear axle but the studs don't fit through. The knurled part of the stud is much thicker than the frame rail. Also, the bed floor is intact... no holes of any kind.