Project Planning Advice

I am trying to decide next steps on my Tundra, and I am looking for some input. I have a 2003 4.7L V8 2WD Access Cab, which is rust free and very well-maintained. (I am the original owner.) I recently acquired a 2004 4.7L V8 4WD Double Cab, which has severe frame rust on the front passenger side (not safely driveable), but it appears to have been relatively well-maintained otherwise.

I am currently living in the Midwest (IN/IL) region, so I would like a 4WD vehicle.

I am considering a few options:

1. Rust proof and preserve/maintain the 2003 2WD, and try to repair the rust in the 2004 4WD.
2. Rust proof and preserve/maintain the 2003 2WD, and try to find a new frame for the 2004 4WD.
   
3. Cannibalize parts from the 2004 4WD to make the 2003 into a 4WD......is this possible? I have seen DirtJumper's post, but I don't know if there are any frame discrepancies that I should be aware of.

What do you guys think?

 

I'd prefer to see pictures of the rotten frame before making a call on it. There *are* at least some repair pieces out there you can utilize to fix the frame. But I'll toss out some comments.

Are you sure the 4WD is working on the DC?

I think #3 is a hell of a lot of work with tons of obstacles to solve for, but it's technically possible as long as all expected mounts match on the frame. DC frame is different from AC/RC frames, so you're sort of SOL on a body swap, and may be SOL on a drivetrain swap - I'm not 100% sure.

I think #2 is a great option, but only if you're ready to put in that work, it's no laughing matter either. I take it you found this already, right?

I think #1 is the most practical option on that list.

 

Thanks shifty! Yes, I saw tmcginley's post, and it definitely was a lot of work. FWIW, I do not have any experience welding, but I am willing to take the time to learn. I have a week off coming up in October, and I'll have access to a lift. So, I think that I could accomplish #3 if I can swap the drivetrains without any siginificant body work.

Here are pics of the framer rust:
Front Passenger

Front Driver

Rear Driver

Rear Passenger

 

You will need significant learning time before you are able to competently tackle the welding/repairs of that frame. Something like a few thousand hours of time. Also your fabrication and fitting skills will need to be up to par. The rust and bad material extends far beyond what it looks like now and it's likely that you will need to remove a significant portion of the frame to get back to good material.

Not saying it cant be done, but if you're really interested in learning to weld start now and save that project for couple of years from now.

I have all the skills, tools, and experience to do a job like that and I probably wouldn't even bother. You will be time and money ahead to find a replacement in better condition.

 

The DC frame is toast. Best to cut your losses on that one. Good chance the hardware for the 4wd is going to be inop or extremely rusted as well. Hopefully you didn’t buy the DC and are not having to realize a loss on it.

 

I got the DC for the cost of the new tires, so it's not a loss. I have driven it around local roads at low speed, and the 4WD seems OK. The rest of the car is in remarkably good condition considering the frame rust. That being said, I see your point @KNABORES and it would suck to do the swap only for the 4WD drivetrain to crap out in a few thousand miles.

@JakeJake 1000's of hours? Yeesh. I was looking at using the Safe-T-Cap components to avoid the fabrication and fitting issues.

 

What are you gonna weld the safety cap to? The frame in general is rusted and has perforation in multiple spots. Have to have a clean and sturdy metal surface for the safety cap to get welded to, not sure yours has an acceptable landing zone for them.

 

Yes. That may even be on the low end. It's overhead vertical and out of position for much of it. You will struggle to produce an acceptable weld even in the flat position without some serious practice.

Anybody can pick up a mig welder and stick two pieces of metal together, but it takes a whole lot more understanding and skill to do it at an acceptable level of quality.

 

Damn, yeah. That's toast. Almost looks like it's been underwater to me, but it's weird, I'm seeing some new-looking fasteners under there, like on the transmission mount.

There's no welding to solve that. You're basically looking at a frame swap. You'll need to find another DC frame to get that done.

 

This usually seems to be the story

 

Can I add option 4? Sell both and get a working 4wd?

There are folks out there willing to tackle the frame replacement and so the DC should have some decent value. If the body is in good shape, just the bed alone is worth money.

Otherwise I'd go option 3 assuming the parts will work.

 

Welding is an art as much as it is a science. One does not merely weld within a matter of hours. It takes a lot of practice and studying. Root pass, fillet sizing, weld puddles, porosity, undercut, types of metal being welded with what filler material, amperage, blowout, joint design, SMAW, FCAW, TIG, MIG, etc. There is A LOT to learn. I bought my own hobby welder to do small stuff around the house. The duty cycle is sufficient for what I need and it's 110/ 220V autosensing. I'm an electrician by trade not a welder, but I like to learn things. I've worked with some great welders who taught me what I know. Can I weld? Yes. Does it look pretty? No. But it won't fall apart. As they jokingly say," the bigger the blob the better the job" and "What makes a good welder? A good painter." LOL.

 

I actually really love this idea ^^

 

@rock climber @shifty` I do not think that I could ever sell my 2003 Tundra. It was originally my dad's when I was in high school before he gave it to me after college. Maybe, I am overly sentimental, but I cannot imagine parting with it. I am leaning towards option #2 (frame swap the 2004 4WD).

@BlueCrushSC16 I appreciate that......kinda makes me want to do it even more though....or at least try.

 

I think that's a great reason to keep it!

If you have the time and space frame swapping would be a great learning experience.

 

We love spending other peoples money

That said and as a 2004 DC LTD 4WD owner, I suggest #2 also.
IF, lot of work IF, you can do the work your self.

 

Alright, I'll move forward with option #2 (Rust proof and preserve/maintain the 2003 2WD, and try to find a new frame for the 2004 4WD).

Now, I just need to find a rust-free double cab frame........

 

How far are you willing to travel?

 

@shifty` Easily as far as ATL!

 

I'll keep eyes peeled. Meanwhile, you may want to start with more-local feelers at www.car-part.com

 

Can we talk you into doing documentary of the restoration?

 

I am rather mechanically inclined. I am also sometimes a masochist when taking on projects. I would not take on the frame swap of an eaten out Tundra. The frame is not the only thing rusted. Everything will fight you and many things will need to be replaced. The money (and time) a project like this will cost you could easily be avoided by selling the 2004 for a profit and buying a decent non-rusted DC. Or use the profits to fund the AC 4wd conversion. Which is a project I would take on.

 

@KNABORES That is really sound advice. I might just part out the 2004 4WD and save my money until I can buy one without as much rust.

Thanks for everyone's input!

 

Have you tried taking it to dealer for frame recall?

 

Might have missed.....2004 4.7L V8 4WD Double Cab....was not part of recall, 00-03 only

 

I’d still call Toyota. Worst they can do is say no

 

I tried, no dice

 

Not my ad but remembered seeing in my local area Early 2000s Toyota parts truck, have tires , good transmissions , bad motor from what I’ve been told . , what parts you see is what’s left

 

Frame looks good

 

Thanks @weadjust ! I appreciate it