Is this frame rust fixable?

[2006TJ1]

On my TJ, the first TJ we bought, we had no idea frame rust was such an issue. The body was clean, interior was clean, it had relatively low mileage, etc, etc. Since joining the forum and becoming more informed, I knew that frame rust IS a serious issue.... I've been putting off finally checking it for a little while, trying to hold on to the bliss of ignorance, but I knew that was a stupid idea. I will post some pics up shortly.

There are no visible holes in the frame. The outside has almost no surface rust at all. The inside is a different story. I know it can be beaten off with a spinning chain, pressure washed, and pulled out with magnets, but am I too late for that? Do I need to look into SafeTcaps?

 

[2006TJ1]

 

[GeorgeSully]

It looks fixable but I would start with a air hammer and chisel attachment to break off the big stuff and use an interior coating made to spray on rust like something from Eastwood.


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[2006TJ1]

It looks fixable but I would start with a air hammer and chisel attachment to break off the big stuff and use an interior coating made to spray on rust like something from Eastwood.

That's the plan, if its worth my time to fix... I've read the write up from @Wade and he did an extremely thorough job so I will follow that.

 

[JDS123]

Hard to say from the photos. I would first give the areas around the holes a pretty good whack with a hammer. If it starts to break apart, then you need to look into safety caps. If it doesn't break, I would power washer out the inside of the frame. Then spend a day with a magnet getting all the chunks out. Then power wash again and hit it with some internal coating.

It doesn't look dangerous, so you can try to prolong how much longer you have. Inevitably, it will probably need some attention, but maybe not right now.

 

[2006TJ1]

FWIW, I am in Georgia and will stay in GA, so we never ever have salted roads. I would assume that will reduce the progression of it if/when I do a thorough internal coating.

 

[TJ2]

Frame swap if that is mine.

 

[2006TJ1]

Frame swap if that is mine.

What's the motivating factor for a frame swap over safety caps?

 

[GeorgeSully]

What's the motivating factor for a frame swap over safety caps?

Safety caps I assume for smaller areas but a frame swap is the ideal solution.


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[JDS123]

What's the motivating factor for a frame swap over safety caps?

That is a fairly large discussion. My Jeep goes in for a frame swap in 3 weeks, so I've done a ton of research on all the options. While some say that safety-caps are a long term solution, my view is that they are a bandaid (and most big Jeep shops I've talked to seem to agree). If you want to get 2 more years out of a Jeep, then go for the safety-caps. If you want to keep it forever, do a full frame swap.

Again, this is only my opinion. There are plenty of people who have safety-caps and they're doing just fine. I plan to outline everything in a huge frame rust thread that I'm going to post when my frame swap is done.

 

[TJ2]

What's the motivating factor for a frame swap over safety caps?

Cost and longivity. You do the math and total cost will be almost the same. and the longivity is far apart.

 

[2006TJ1]

I would have to get an inspection camera of some sort to investigate more, but I believe majority, if not all of the rust is located in the section of the frame between the front and rear tires; the flat portion between the wheel arches. A safety cap kit for both center frames is around $400. What does install labor normally cost?

@jodomcfrodo if you don't mind me asking, how much are you paying for a full frame swap?

 

[JDS123]

I would have to get an inspection camera of some sort to investigate more, but I believe majority, if not all of the rust is located in the section of the frame between the front and rear tires; the flat portion between the wheel arches. A safety cap kit for both center frames is around $400. What does install labor normally cost?

@jodomcfrodo if you don't mind me asking, how much are you paying for a full frame swap?

I'm paying 1.25-1.75 times what my Jeep is worth in total for my frame swap, but I'm also adding in a ton of extras. For example I'm getting a Savvy TT and I had my new frame powdercoated. The cost of the frame swap really depends on what extras you add in. With the whole Jeep apart, it just makes sense to do a lot of work. All in all, it makes much more sense to just get a new Jeep.

A quality safety cap job would probably run $1500 - $2250 total.

I'm still not convinced you need any frame work done. Some more pictures might help. Can you reach in and easily pull large chunks out of the frame?

 

[TJ2]

I would have to get an inspection camera of some sort to investigate more, but I believe majority, if not all of the rust is located in the section of the frame between the front and rear tires; the flat portion between the wheel arches. A safety cap kit for both center frames is around $400. What does install labor normally cost?

@jodomcfrodo if you don't mind me asking, how much are you paying for a full frame swap?

Labor is estimated as $100 per hour. Cost of equipment is 1/3 of labor. Cost of material is about twice of equipment. Depreciation value is 17% every year. So do the math... what do you have left in 10 years?

 

[2006TJ1]

I'm still not convinced you need any frame work done. Some more pictures might help. Can you reach in and easily pull large chunks out of the frame?

I can try to take some more/ better pictures but almost all of the rust is located on the bottom of the inside of the frame rail, so its near impossible to get good shot of with my phone camera. I can try my absolute best, though.

I'm not sure what large would be, but earlier I pulled out a few pieces that were roughly quarter sized. Edit: On the passenger side, the rust is entirely on the bottom of the inside of the rail. On the driver side, its started to climb up the sides but is only about halfway up.

 

[JDS123]

I can try to take some more/ better pictures but almost all of the rust is located on the bottom of the inside of the frame rail, so its near impossible to get good shot of with my phone camera. I can try my absolute best, though.

I'm not sure what large would be, but earlier I pulled out a few pieces that were roughly quarter sized. Like I said though, its entirely on the bottom.

If you can pull chunks out it is probably too late. I would hit everything with a hammer if anything starts to fold in, stop driving it immediately (or at least don't go very fast). I only use mine to put around town right now (30 mph max). If you decide to go for a frame swap, you have a lot of work ahead of you in terms of finding a frame. If you go for safety caps, then you just need to find a shop. And if you decide to part the Jeep out, let me know. I might buy some stuff off of you.

 

[2006TJ1]

If you can pull chunks out it is probably too late. I would hit everything with a hammer if anything starts to fold in, stop driving it immediately (or at least don't go very fast). I only use mine to put around town right now (30 mph max). If you decide to go for a frame swap, you have a lot of work ahead of you in terms of finding a frame. If you go for safety caps, then you just need to find a shop. And if you decide to part the Jeep out, let me know. I might buy some stuff off of you.

Parting would be my absolute last choice. My friend is a full time mechanic, but also does restorations in his home shop. I'll have to talk to him to see if he has ever done any safety cap work. He probably wouldn't charge me like a normal shop would... we'll see. I'll go at it with a hammer and report back.

I don't have the money to do a complete frame swap as of now, but also do not have the money to get another vehicle, so even if a safety cap is a bandaid, I guess my best choice right now would be a bandaid.

 

[TJ2]

Salem must be a sleepy dull night today. I am surprised Chris is not making any noise on these rusts.

 

[2006TJ1]

A treatment from the hammer lead to a scary discovery

 

[JDS123]

A treatment from the hammer lead to a scary discovery View attachment 60101

Looks very similar to mine. If I took a hammer to mine right now, I could probably break out the entire bottom of the frame near the front control arm mount. I've been driving it a bit since I took the photo below and it is now a bit worse. You can probably still drive it around while you figure out how to get it fixed, but I wouldn't go much faster than 30mph. I'm a bit worried driving mine around right now (and I really shouldn't be driving it at all). That frame, much like mine, is shot. Safety caps look like they might be the best option.