Outer Limits 4x4 Board

Ok got a 92 single cab hilux and have found rust in the chassis just in front of the fixed pin on the rear springs on drivers side. my question is can it be repaired safely enough or legally? i havent started cutting yet but from what i can feel rust is approx 150mm long across the bottom and about 50mm up the side of the rails. any advice will be appreciated..

cheers mick

pictures can tell 1000 words...

uh gawd damn thats pretty nasty!

That looks like it needs to be cut out, plated up and welded. Then fish plated over the top.

If its a registered car, get it done by a proper vehicle repair shop.

checik the rest of the chassis through out to make sure its worth the time to fix it. Looks easy enough and vehicle standards cover chassis welding so it will be leagal. Also wheel base length alterations are covered too, which involves cutting the chassis right in half. So it can be repaired leagally.

wow - thats nasty and in a terrible spot!! i wouldnt be driving that like that!

mate id just grind it out put some primer up the inside of the rail and wled some 10mm plate in
wouldnt worry bout getting anyone to do it if you know a decent welder.
just flap disc it and paint it and it will be fine.
id say your mechanic isnt gonna check every bit of your chassis

Had the same thing in a 60 series a long time ago, it was right beside the rear spring hanger,
had an engineering joint in maroochydore plate it on three sides for a fair length either side of it, only cost I think $400 odd about 9 years ago.
I treated it with rust convertor and put an electric thingo on it to stop the rust any further. was good for a few more years untill we sold it.

I wouldnt go outback with it but I would probably still drive it till it got fixed, (based on the fact that had you not looked you would still be driving it)
I would fix it SOON.

Theres a good reason the hose out the mud from inside your chassis rails from time to time.
See this a lot on 40 and 70 series. Normally dried mud inside.

Bazzle

No wonder so many hiluxes snap the chassis just behind the cab.
Get it repaired by a chassis works (EG: truck lengthener) or replace the chassis.

Just noticed on my Gq that I bought a couple months ago the rails are basically half full of dried up mud pretty much impossible to get it out

bang the rails with as hammer to loosen it up then chuck the front up in the air n jam a hose down the rail/s.....

Would scrap it & get a new one..
If it is that bad there chances are the whole chasie is screwed..
Once you start reparing it will not be long before you find more weak spots..

I have heard of people pouring diesel into the chassis rails to prevent
rust, the diesel fuel evaporates away and leaves an oily film to protect it.

I dont know if I would use diesel myself, but the principle sounds good.

That chassis is full of cancer now. Not worth fixing imo. Unless you won't be keeping it and don't intend on giving it a hard time. Better of sourcing a good wreck and using that.

chpd80 wrote:I have heard of people pouring diesel into the chassis rails to prevent
rust, the diesel fuel evaporates away and leaves an oily film to protect it.

I dont know if I would use diesel myself, but the principle sounds good.

Would you use CRC or WD40?

That would probably do the same thing but I think it would be impracticle as you would use heaps of it.
I think the idea is to pour it down the chassis rail then drive around lettting get into every little nook etc, then it dries out leaving the protection of the oil, (or whatever is left of what you use)

Good thought though

Maybe get the internals of the chassis rails sprayed with boiled fish oil or linseed oil. No point on a chassis thats already on it's way out.

ok quick update i have cut out most of rust with the exception of about 15mmx 200mm on the inside of the rail,(only had one cut off wheel)and have looked with a torch further down the chassis rail where i have cut, and it looks mickey mouse, so fingers crossed the other side is ok. my next step will be to weld in some new steel then overlap/fishplate the inside for added strength. then block all drain holes and fill the chassis with deisel...

Looks like you might have got lucky and cut it all out,
My 60 series had it localised in just one chassis rail in one spot,
Have a good ol poke around (I mean a good bash) with a big screwdrive along the chassis to see if you have any more spots.

Let us know how the diesel trick works for you, I know a few guys who'
swear by it. Obviously better to do it from new, but its better late than never.

please do this right ..... pick off the rear spring hanger and the tray mounts.... you can see in the first photo that it is cracked behind where you have cut it, in the spring mount and tray. Clean it all back with wire wheel/ flapper to see any further cracking not just rust, the replace chassis bits and fish plate(use the same thickness of chassis material or slightly thicker 3-4mm) on the OUTSIDE atleast 100mm past last welded joint/or crack that has been fixed.. dont do the dodge not worth it

nastytroll wrote:

chpd80 wrote:I have heard of people pouring diesel into the chassis rails to prevent
rust, the diesel fuel evaporates away and leaves an oily film to protect it.

I dont know if I would use diesel myself, but the principle sounds good.

Would you use CRC or WD40?

No... those chemicals evap away, only good for very short term lube.

Bazzle

Isnt it Diesel mixed with old oil the way to go..... Or just fish oil. If you do a good enough job you should be able to get the repair blue plated.

Cris