Rusty Frame Perforation - How worried should I be? - Safe T Cap?

I recently noticed a crack forming in the frame of my truck at the mid-rear section under the drivers side rear wheel well. When I poked at it, large pieces of rusted frame fell loose very easily, revealing a gaping hole. It was a real punch to the gut as I recently sunk a lot of time/money into the truck putting all new suspension lift, wheels, tires, head unit, exhaust, repairing valve cover gasket leak, etc.

I did take the truck to a Toyota dealership and had the frame undercoated back when the campaign was going on and I bought the truck around 2008-2009. From my research, the campaign officially ended in 2020 from my understanding, so a little late to the game for a whole new frame option. I believe I can fix this with a Safe-T-Cap from AutoRust technicians and already have it in hand, but looking for input from the knowledgeable TW folks here on the following.

1. I stopped driving the truck daily to work based on the condition seen here, but it is causing a major inconvenience for my girlfriend and I sharing vehicles. Should I be that worried about it completely giving way? Seems like minimal material here, but interested to see if any others have experienced same/worse with no issues.

2. Safe T Cap install and long term success? I've watched a lot of videos and read a lot of information on these frame repairs. Many seem to have great success with them. Just looking for feedback, advice, pointers on those who have gone down this route. My plan is to install the Safe T Cap, then clean up the rest of the frame, fluid film everything, ride this truck out for another 3-5 years.

https://www.autorust.com/product/tacoma-rear-frame-section-bump-stop-left-driver-side-tac-156u-l/


Thanks

 

time to take the bed off, cut the cancer out and put on new frame ends. That's compromised pretty bad. Not safe to drive most likely. You never know when somethings going to give.

 

Yikes, that looks like it could fail at anytime. Sorry especially after all the mods. Have you checked the rest to see the condition before making a game plan

 

I have bad news, and it's that if you're rusting out up there... you're nearly guaranteed to be rusting out around the leaf spring main hanger as well. I had to fix both on mine.

























You probably won't weld in the spring hangers, I took the opportunity to convert to longer Chevy leafs when I did the work. But feel free to ask questions

 

I would go over the whole frame with a hammer and see if you can punch any holes in it elsewhere. Then you’ll know where you stand.


What you’ve got there looks like it can be fixed, but there is probably more.

 

Thanks @Speedytech7 . Appreciate the detailed feedback and pictures here. I'm sure I will have more questions once I get into it!

 

Check the rail by catalytic converter and passenger side top shock mount with a hammer too.

 

The real question is it will be comprised in more places .

This is going to turn into a major frame overhaul.

Safety Caps are an expensive option when you do not have the time or skills to fabricate your own replacement parts

Be nice to know where the Truck lives.

Best of luck.

 

Where are you located? I see full frames come up now and then on facebook marketplace. Saw one yesterday that was even SAS for $750

 

Well, last weekend the Safe-T-Cap was welded over the frame after cutting out / cleaning up the cancer. We didn't have to take the bed off or drop the fuel tank to weld the safe-t-cap over the frame, which some might say isn't the "right" way to do it. But, I was on borrowed time in a friend's shop and I myself do not know how to weld so I was paying him to as he is a professional welder. I was happy with how it came out, and know it will save the truck for years to come. Going to fluid film everything now!

 

It is always the welders calls as to what to remove or not.

Some insurance policies mandate removing fuel tanks for any hot work.

 

Are you saying if you can't punch holes in the frame the frame is, ok? How hard should one hit the frame? What type of hammer should one use?

 

I am selling mine, despite all the work just put into it to make it perfect! Unfortunately have not been able to post in the for sale section here because I don't have 50 posts racked up on this account. I lost my old one and could never recover it. Been on this website for the 14 years I've owned the truck! LOL

 

It’s an easy indicator of something that’s pretty far gone. If you get a bunch of holes from the exercise, then that may signal it is beyond repair. Whether the frame is overall sound if you don’t put holes in it … it’s a good sign, but it might be worth checking more closely.

Use whatever hammer is handy, hit it as hard as you dare.

 

Good luck. I hope you disclose the condition to the buyer.

 

If the hammer puts holes in it, it was gone long ago. If I see any separation where cross members or brackets are riveted to the frame, paint lifting/bubbling I am not going to waste time trying to repair. These frames were lacking when new. I feel bad for those that live in the mid west/east.

 

Oh yea - for sure. I've honestly made sales easier in the past by being overly transparent. Had a salvage title BMW I was driving around for a bit after someone swiped me but didn't affect the function of the car at all. Just pushed in rear fender, but caused enough damage that they totaled the vehicle. Put a big detailed description together on FB marketplace. Guy told me he bought it because I was the most transparent person he's ever dealt with when purchasing a vehicle. Ha! Asking for bad karma hiding stuff like that.

 

Anything can be fixed !! If you have the skills and the equipment and a nice place to work.

A labor of love more then anything else.

I really need to take pictures but not having done it most of my life it is so far down on the list I forget.

Besides anyone I would show could see it in person.

Being cost effective is a whole other story.

 

lol that’s not a crack that’s a full blown hole brother. If you can’t weld, find a good welder and like you already know safe t cap.

 

Looks good!