Safety Cap frame repair

Got a new to me 2009 double cab in what I thought was great shape, low mileage (just under 100,000) frame looked decent for Ohio, and panels the cab and bed where in great shape. Well decided to dig further and found some major rust under the spray coating that Toyota did. Needled it all off and low and behold two nice holes on both the driver and passenger side under the front doors. Just one year past recall so dealer wouldn’t do a thing. Local frame repair guy said not until January but if I could weld I should give it a go. So I bought some Safety caps and some Mastercraft rust sealer and am going to town. Here a couple photos from today’s repair.
After cutting out the worst of the rot I cleaned out the inside of the frame and brushed a rust converter in it. Plan on oiling the crap out of it once a year from now on.
Unfortunately as I took it for a test drive after install I got about 5 miles and heard a loud clunk from the front end. Turns out I must have stiffened the frame so much that the front passenger side spring broke it’s rusted out seat and popped down to the control arm. Luckily I already picked up a new set, just didn’t plan on doing that tomorrow!! Was actually happy it wasn’t my welds!

 

Nice repair on a ugly hole.

 

Thanks, got my new front shocks in today after the passenger side spring seat snapped from the stiffened frame. Going to weld up the driver side tomorrow. Not near as bad as this side was. Anyone else attempted these repairs? Wondering about longevity? Guessing I’ll check the welds every couple weeks for awhile to make sure every is holding strong.

 

You might want to try and turn your heat up on the welder. Seeing some cold welds there...hard to see for sure in your photo if you have good penetration.

 

I agree, some spots are good some are not so much. First time welding on my back and upside down ( I swear my other welding looks better), actually thinking of grinding a few spots out and re welding places? Does that make sense to do?

 

I've got front section Saf-T-Caps going in shortly.

The install instructions recommend cutting out the bottom of the frame in the areas underneath the cap both for fitment and also post-install drainage. Did you end up doing that or not? How was the fit?

 

I didn’t cut the whole bottom out, just where it was really bad. Where there drain hole is was fine so I plan I drilling it out. Fit like a glove even without the hole bottom being cut out. Used my jack and some clamps to help hold it in place while tacking.

 

I like it! If I had a frame like that, I'd be doing the same thing. In fact, that would finally be my justification to buy a lift.
Once you get your patches in, I'd spray it with some Rust Oleum, let it dry/cure for a week or two then hose it down inside and out with the rust preventative flavor of your choice. I'm actually pretty fond of the Dollar General WD-40 type stuff. It has a little body to it.
I like Fluid Film but don't think it wicks well, into the small sandwiched areas. I usually FF, then follow it up with some lower viscosity stuff. My frame is pretty greasy and rust free.
Keep us posted!