My frame rust repair adventure

[ca2kjet]

Back in 2018 I started to clean up some of the surface rust that was occurring on my frame. Things weren't too bad back then but life got in the way and it was one major event after another. My 2007 Avalanche is my daily driver and I've racked up over 230k miles on it so far. That's 230k miles of rust belt driving and Massachusetts sure loves its salt. Takes a massive beating on everything if one doesn't keep up with maintenance.

Fast forward 6 years with that lack of maintenance, and well, my frame is in bad shape. Very bad. So bad that it won't pass state inspection. I could source a brand new frame and reached out to a number of places to see about doing a frame swap (and I made it clear I had no problem paying for that type of project) but kept getting "No" for an answer. I think it was the age and mileage of my truck that scared everyone off.

It seemed as though I was destine to scrap it or find a buyer in a state that doesn't have the state inspections we do. I can't imagine not having my Avalanche and the thought of losing it worried me. It's been a huge part of my life between personal adventures, Boy Scout events, home improvement projects and on a very personal note connects me with my father who passed away a few years ago.

Luckily, I found a fantastic shop that specializes in frame rust repair that wasn't too far away from me. They do everything from replacing sections with new components to full custom fabrication. They performed an extensive inspection of the frame, banging, poking, prodding everywhere and everything to confirm the condition of all the metal. When all was said and done they reviewed the damage with me and I asked "So, can it be saved?". I was relieved to hear them say "Yes" and didn't care about costs at that moment.

They provided a full workup on what needs to be replaced and I got a quote for $10k. Some may see that price tag and run the other direction. I saw it and said "No problem, let's get this scheduled."

After waiting three months, it's about to go into the shop. These are the components being replaced/rebuilt.

• Front Left Center Frame Section
• Left Center Frame Section
• Left Frame Section (over axle)
• Right Frame Section (over axle)
• Cab Mount (front left)
• Body Mount (center rear)
• Body Mount (rear)
• Coil Spring Bucket (right rear)
• Coil Spring Bucket (left rear)
• Spare Tire Cross Member
• Track Bar Cross Member (rear)
• Bump Stop (rear) Set

I've added the inspection photos to a gallery album but be warned, it ain't pretty!

+14

Frame Rust Repair

• ca2kjet
• Sep 27, 2024
• 23

 

[EXT4ME]

I approve of this post.

Anyone that has seen my posts over the years knows that I am not afraid to spend money to keep my trucks in the best shape possible.

In the case of each of my trucks, I have easily spent more in maintenance than what I spent to buy the trucks initially.

For the 2003 Avalanche that I bought used in 2020, the purchase price was quite low and the amount of money spent on maintenance would not have to be very large to surpass the purchase price.

However, when the 2004 EXT was purchased used back in 2012, it's price was considerably higher.

At the beginning of 2020, I was looking at having a new engine installed in the EXT at a cost of around $9,000 and that repair would have made my total maintenance and repair costs exceed the original purchase price by a pretty good amount.

Luckily, the final repair to the engine ended up costing quite a bit less, but I have still already spent close to the original purchase price of that truck.

Still, my philosophy in regard to my trucks has been since I was fortunate enough to buy both of my trucks for cash, meaning they were paid for from day one, I am in a better place to be able to spend maintenance dollars to try my best to keep them in the best shape possible.

But, also important to consider, since just due to their age and mileage, neither truck is worth a great deal in terms of a trade in, so it is highly unlikely that I will ever be able to afford a "new" truck ever again.

So, it makes sense to me to spend what I can afford to spend in hopes of not having to buy some other used vehicle that I know nothing about and having the start the whole process over again.

In the case of your truck, I agree with your repair plan, especially since it will give you a good chance to do the proper preventative measures to extend the life of the truck well into the future.

Well done!

 

[MS03 2500]

That is a lot of rust good luck with the fix. I have to touch up my frame every year.

 

[frito]

How are the rockers and rest of the body? My frame is mostly good with on soft spot but my rockers are toast. $10k actually makes me optimistic as I was figuring $20k or more to get it where I feel like it will last another 20 years. Just can’t stand the new stuff and no way I’d dish out $50 - $80 grand on something I don’t care for.

 

[ca2kjet]

How are the rockers and rest of the body?

Honestly not that bad. The driver's side rocker is nearly perfect while the passenger side has some issues towards the rear but it's in an area that will be repairable and hasn't become too cancerous.

There's some issues with the rear quarters but it's a small area towards the bottom on both sides. Body rust will get new sections welded in. The plan is to get all that taken care of in the spring. I held off doing it this year when I discovered the frame issues. Now that I'm expecting a good foundation to work from I should be able to get this thing in tip top shape again for many more miles of fun.

Oddly enough, going from the gas tank forward, everything under my truck is almost pristine.

At this point, if the engine blows up, I'm rebuilding that too.

 

[ygmn]

makes me want to get on my creeper and slide under my truck for inspection...

I can say living in the south without road salt we - never see this unless someone drove on a beach into the gulf of MExico.

Good luck

We need an award or something for peeps that extend the life of their truck by going above and beyond what "Normal" people would do.
When I say normal I mean peeps who do not understand the Avalanche concept

 

[bacs22]

They provided a full workup on what needs to be replaced and I got a quote for $10k. Some may see that price tag and run the other direction.

I can 100% understand where you’re at! Only you can determine if the $10K is money well spent, but I’d do it for mine in a heartbeat.

 

[ToyHauler13]

Luckily, I found a fantastic shop that specializes in frame rust repair that wasn't too far away from me.

Good for you!

That IS some serious rust! They LOVE that salt here in northern Illinois too. If there is even a light snowfall predicted the salt trucks are out spreading salt in preparation of a snow we may not even get . Some times the streets are as white with just salt as they are from a light snow. Drives me crazy! My town in the last 5 years is spraying the beet juice (?) or something at least first instead of salt.

My 2013 is not bad and I would like to keep it from rotting out like another vehicle did that I owned. Others on here and two of my neighbors spray their frames and that got me doing mine last year after weeks of scraping etc. flaky surface rust in preparation. From the rear axle back I brushed on that POR paint on much of that cleaned area and sprayed the creeping oil coating over that .
Like yours the rear third of the frame was the worst with the front 2/3 still with the factory protective coating with some areas of it peeling off. If I can keep up with any areas not adequately protected I think it will survive fine.

I am lucky now I don't have to take it out daily and can usually avoid driving it in the salty slush a few days or more after a snow.
I also don't mind spending some time and money on this truck to keep it as close to new condition as I can. I have never liked any vehicle I've owned as much as this Avalanche!

Good luck with the frame repair!
I'm sure you will post some repair pictures.

 

[ca2kjet]

It has returned!

After a lengthy wait due to some part delays and discovery of some other bad areas, the frame is completely repaired. Just picked it up on Tuesday and wow what a transformation. Definitely worth the wait and I'm good to go for many more years. I never would have thought my crumbling frame could be saved.

+17

Frame Rust Repair Process

• ca2kjet
• Nov 7, 2024
• 26

 

[ToyHauler13]

I never would have thought my crumbling frame could be saved.

Dang!! That looks great!

 

[CarMech1969]

Good stuff!
Be sure to oil the crap out of everything prior to every road salt season to let the oil creep into all the gaps - and keep getting it done regularly - and it should last for darn near forever lol

 

[frito]

Amazing transformation

 

[ca2kjet]

Good stuff!
Be sure to oil the crap out of everything prior to every road salt season to let the oil creep into all the gaps - and keep getting it done regularly - and it should last for darn near forever lol

This 100%

Wish I had done that over the years. I now have an air sprayer for undercoating. Plan to do it every spring and fall.

 

[redheadedrod]

Have a shop near me in PA that would do that job. Would probably have been better to get a new frame and go that route but looks good. I would be concerned that parts of the frame that were not addressed will continue to rust and have to do more of this in the future. I am actually thinking of having the rear frame rails strengthened to better support towing as I have heard the rear frame can slowly bend down if pulling large loads.

Plus my 1500 was totaled because that area is considered a "crush zone" and folded under that truck totaling it.

That shop I mention will be doing some rocker and rear panel replacement on my 2500 probably next year. I will likely have about $5k into it. The rusted sections are all under cladding and the truck is white so it shouldn't require any oddball painting.

Also doing an engine swap from an 8.1 to a built 8.8 which appears as if it will have double the power of the original 8.1, the HP and Torque will both be double the original numbers. That will cost me about $12k with nothing else included.

Had a new transmission built for it with better components to handle a little more power. One of the coolant lines came apart and took out the transmission.

I paid $5k for this truck with a known bad motor (Still moves and hauls fine, just has serious lifter tick / piston slap and I expect it to just seize up suddenly). I priced out decent used 3/4 1 ton trucks and nothing was available for less that $30k that I wouldn't be scared of. With newer trucks being insane. I figured if I do $15k in upgrades to a truck I spent $5k for I know the truck is pretty much new and shouldn't need much. The brake lines had already been replaced and about to do the fuel system.

Definitely think its worth it to fix these trucks up. Especially if you can do it before they require such an overhaul. I don't plan to drive mine in the winter where its going to have to deal with any further rust however. But I got my 2500 solely for towing and as a backup vehicle.

 

[michaelhicks66]

I'm going to be doing both rockers and cab corners in the spring. Not worried about matching paint. Just good coverage then going to wrap the truck. I figure it should last as long as I probably will! Lol
But I love the Avalanche. For some reason it's just the perfect truck!