Awhile back, I broke a gas tank strap. I’ve since only put about 1500 km on it since then (second vehicle). I crawled under neath today to fix the strap situation and noticed the frame has some good rot happening before the front spring hanger (not to be confused with shackle).

I am more then comfortable in welding a repair in place and have the tools and experience to do it. What I’m asking is if I should just patch this spot and clean the rest of the frame up with a wire wheel and look for other areas OR cut the back half out and rebuild with rectangular tubing?

Plan is to eventually turn it into a wheeling only truck with 33-35” rubber and a SAS up front.

Go full stupid now or be sensible and fix what only needs to be fixed given our current world situation.




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Went out there with a flapper wheel on a grinder and cleaned it up. Not as bad as I thought it was going to be.

Should I use 3/16 plate on the bottom and overlap it on the sides to get good weld and penetration or just use angle iron and weld the top and sides?





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