Another Rusted Frame

My 2004 SR5 DC with 228k miles has a solid frame all around, except in two locations. Always driven in the NE. Runs like new and looks great inside and out. I'm considering fabricating steel plates to wrap around the damaged areas and welded in place. Next I wanted to sand the frame (sand blasting what I can) and then applying POR15. Are the damage areas more severe than what I'm thinking? It looks like a pretty straight-forward repair on a frame that (my opinion) is still repairable. Damage section #1 is near the drivers side of the steering rack. Section#2 is long the side of the frame about 8" to the rear of the front left mudflap. Thanks.

 

If it were my truck, I would be thinking like you, but yes, the damage is much worse than you hope. It’s more like what you’re trying not to think. There’s extensive delamination of the steel in just the few pics you’ve shown. Swollen and crispy looking. Poke around with a hammer and see what’s solid and what’s a little soft.

 

I have similar damage to pic #2 by it’s actually rusting from the inside out. Take a pic inside the frame rail looking down into the boxed sections and you’ll see what I mean. I would recommend autorust.com to get the precut $500 section metal wraparound to cover both sides. Only welding required.