2006 frame rust near drivers side catalytic converter

I bought an 06 double cab a couple weeks ago and thought I’d really inspected the frame good before buying . Unfortunately yesterday while installing new tires I found a bubble on the inside of the frame right by the drivers side catalytic converter. I plan to take the exhaust out of the way, cover the gas lines, cut the rusty section out (including whatever rust is behind first layer being that it’s double walled there), spray everything inside with Eastwood rust encapsulator, weld a plate over it, then commence to scaling and roughing up entire frame with wire wheel and needle scaler and paint everything with Eastwood rust encapsulator. Any of y’all patch one in the same area with long term success, or have any good pointers? I’m very capable with welding and cutting. Just have a few concerns with that being double walled in that area. Really just a small bubble like 2”. But I’m concerned more with what’s behind it after I cut it out.

 

Welcome to TacomaWorld
Coroseal rust converter and primer performs better with welding.
I recommend welding before applying but sometimes you can't.

 

Yeah I know whatever I paint behind what I cut out is just going to burn off when I weld it but what do you do? ‍♂️

 

Eastwood and other companies make extension wands with a 360° spray tip so you can coat the inside after it's all welded. I'd look for that, and also look into Woolwax lanolin coating which can also be purchased with the 360° tip. Dual layer approach, reapply the Woolwax periodically and you should be fine.

 

Yeah I’ve got the internal frame coating with the 360 wand ordered. I’ve used it before with good results. Just afraid of what I’m gonna find on that second layer after I cut the hole out. No amount of paint will fix something just flaking away. The entire rest of the frame just has some slight surface rust though and only 160k on the truck… got what I thought was a helluva deal on it in this ridiculous market.

 

Coroseal does not replace metal that has already corroded away weakening the frame. It does however stop (or slow down) corrosion that has already started.

Welding a new section in (done correctly) can add strength back into the frame. Coating that with Coroseal will keep it there.

 

Coroseal converts Iron Oxide (rust) into its inert form Magnetite that won't burn away. It will loose effectiveness as primer for top coat after burning.