Advice on 68 RR front frame rail rot

[TexasRoadRunner68]

Hey guys,
I was rebuilding the brakes so I could actually move the car under its own power and noticed a bit of rot in the front driver frame rail. The frame is solid everywhere else, even under the battery. It looked like a bunch of debris was stuck in the rail where it rusted through. It's a big project, but I don't want to change cars or rebody it. It goes through both sides of the rail and has pinholes on the bottom. It is about the same width on both sides.

How much weaker is this rail? Will it need a patch or full replacement?

View attachment 129671
View attachment 129672
View attachment 129673



Thanks for any input!

 

[cdr]

http://autorust.com/store/

 

[flypaper]

replace it with original metal.
those rust caps are only a cheap bandaid that will devalue your car.

 

[Pistol Pete]

Get an awl and start poking it HARD front to back. The weak areas will show up here and help you determine whether or not complete replacement is warranted.

 

[TexasRoadRunner68]

I have poked the rest of the frame with a screwdriver pretty hard. Everything else seems solid. It's even good under the battery tray. It is about the same size hole on both sides. I am probably going to get a replacement rail (prefer one off a stripped car, but repro works). I figure this could just be patched, rather than a full replacement. It is currently on jackstands and supports its weight.

 

[Pistol Pete]

Do yourself a favor and source an original rail. They are not hard to find and any aftermarket piece can vary slightly, giving you fitment issues.

The hardest part about scabbing a piece in is getting the inside of the frame rail clean enough. You'll want to make a slug to fit inside the frame rail first to add strength to the repaired area. Support the car well and take measurements (plumb bob to the floor for ex.) in several spots before you cut anything. This will help you determine if anything has moved after you remove the offensive piece.