359 Pete - What would you do?

There are a few options you have to keep it on the road.

1. Re-rail the truck, replace all crossmembers. Most expensive.

2. Cut the frame off behind the cab, replace rails from cab back. Sleeve the spliced area. Done correctly no one will be able to tell.

3. Remove the double frame. Sandblast and re-paint rails. Install new 1/4" sleeve from a few feet ahead of the bad area all the way to the back. Replace all the welded crossmembers. Probably the cheapest option. All the holes are already there, just need to punch through the new inner rail and bolt together.

4. Find a complete cutoff with good suspension and diffs, chop the frame off, weld new cutoff in, reinforce the welded area with a new sleeve.

5. Cut your losses and flog the truck as is. I think this is the worst idea because you already know what you have and you'll be buying a new set of problems. I wouldn't waste money and time repairing it if you're going to sell it right away. You will never recoup the costs of frame repair. You're better off to keep running it if you fix it.

 

Option 4....that's what I was saying. He said the suspension was shot in original post. I think this would be the cheapest, fastest, easiest, and best option. Plus the upgraded suspension will make it ride a whole lot better. I think he would be the happiest with this option. IMO

 

You're looking at minimum $4k-$5k for a modern cutoff with good diffs and suspension. Probably about $600 for 2 reinforcing rails. Time wise probably a good 10-15 hours labour to re and re the cutoff and install the reinforcing sleeves. Plus however much time is needed to connect wiring, airlines and things like wheel bearings, brakes, seals etc.

Option 3 is likely more labour intensive but a guy will save a few grand by not buying a cutoff or attaching wiring/hoses etc.

OP, best thing is to weigh your options and see what works best for you. What gets you on the road reliably and safely without emptying your wallet too much.

 

If it's a local daycab I would roll it up to factory. The air leaf suspension brackets are known to wear out. They are cheap and easily replaced. I realize how bad it may look but take a breath and really evaluate the situation. It may not be as bad or bleak as it seems.

If length is that important a cutoff is where I would go next.

 

My W9 had probably 2 inches of rust jacking between the 2 rails at the lower flange. Pulled the sleeves out and cleaned it up a bit and there was still about 75% of the original thickness left on the main rails. It always looks worse when there's 12lbs of rust flake stuck in there.

 

I agree with most. Shorten it back up to 205. Suspension can be reworked or find a late model to stick under it and keep trucking.

 

i'd fix it. you got this truck to the point that you know whats wrong with it. you re open pandoras box with another used truck.

 

I have used rails from scraped trucks as a second rail. Some are taller than others and having a gap at the bottom does not hurt anything if the crossmembers still fit. Also have had steel shops make 8 foot sleeves to reinforce frames. Crossmembers can be a problem and I have custom made some of them. Shorten it sleeve it run it. Just my opinion.

 

What will you take for it as it is? PM me. To answer original question. Fix it and drive it. These newer trucks suck.