[PacoFlacoTaco]

I recently purchased a 2002 Tundra 4x4 off Copart.com for $1,800 (total cost $2500 delivered) as a project truck. I knew it needed a new third member. Unfortunately, the truck has more rust than I originally thought. Tonight I hammered and brushed everywhere I could to find the biggest problems with the rust. I found four areas that are either rusted completely or are thin and look soft when I hammer on them. Is it worth taking to a frame shop to patch up these spots? Any idea how much this should cost? Should I just cut my losses at this point?

The cross member holding the front of the gas tank is rusted through at the bottom. Can this be repaired or should I expect to replace the whole cross member?

Thank you!

 

[festerw]

In my experience once you start cutting to replace frame pieces you end up replacing half the frame. Either get a new frame or part it out.

 

[jdub01]

OP - Are you aware of Toyota's warranty frame replacement program if you live in the northern part of the US where road salt is used? If that's where you are and where the truck spent its life, have a dealer look at it. My truck's frame wasn't anywhere near that bad when I bought it in 2016, and Toyota agreed to install a new frame as soon as the dealer laid eyes on it.

 

[Nick T]

Copart.com purchase, is it salvage title? Dealer may be hesitant to warranty a salvage title. Project truck? How big of a project do you plan? Best bet find a frame from southwest wrecking yard that is not bent and does not have rust. Build your project from the ground/frame up.

 

[irhunter]

I would run your VIN past a dealer...hear their recall thoughts.

Then there is close to zero downside to taking it to a welder, or two, for estimates.

Roy

 

[festerw]

OP - Are you aware of Toyota's warranty frame replacement program if you live in the northern part of the US where road salt is used? If that's where you are and where the truck spent its life, have a dealer look at it. My truck's frame wasn't anywhere near that bad when I bought it in 2016, and Toyota agreed to install a new frame as soon as the dealer laid eyes on it.

Frame rust settlement was for 12 years from the date sold, can't hurt you ask but don't be surprised if it is denied.

 

[PacoFlacoTaco]

Thank you for the input everyone. I spoke with both my local dealer and the Toyota corporate customer service line about this. They both looked up my vin and denied any service because the truck was already sprayed in 2012. It's a little frustrating that this rusting was a known problem and the spray they put on obviously didn't work but I also understand that they can't service a truck forever. Moving on!

Luckily, I work with someone who is an experienced welder - he's the maintenance supervisor for one of our facilities, welding shop at home, brother owns a body shop etc - who has offered to help me out in his spare time. I trust his work and have only spoken with him once about it. I've never had a friend / coworker help me out with this type of project. I offered to prep the surfaces as best I can and plan to bring cookies from the wife but what else should I do? Should I offer to have metal pieces cut to for patches? I'm happy to give him money, I doubt he will take it, but what's a good amount to offer? Thanks in advance for your help.

 

[irhunter]

Show up with some steel you've bought; and beer.

He may not use "your" steel on your truck, but home welders never have enough angle, bar, or plate (your choice).

No need to explain beer, right?

Roy

 

[jdub01]

Frame rust settlement was for 12 years from the date sold, can't hurt you ask but don't be surprised if it is denied.

Thank you for the input everyone. I spoke with both my local dealer and the Toyota corporate customer service line about this. They both looked up my vin and denied any service because the truck was already sprayed in 2012. It's a little frustrating that this rusting was a known problem and the spray they put on obviously didn't work but I also understand that they can't service a truck forever. Moving on!

Sounds like Toyota's selective warranty frame replacement that I've read about continues, and too bad yours isn't covered OP.

My 2000 model year Tundra had the initial warranty corrosion check and frame spray done under the previous owner in 2008 or so. When I spotted frame rust during my pre-purchase inspection in September 2016 and the dealer looked at it, instant warranty frame replacement. My local dealer in southcentral PA still has brand new frames stacked up behind his building, so obviously the replacement program continues at least in my neck of the woods.

 

[R-Rated]

Could you hook me up with the name of your dealer, I would like to have words