Frame Rail Rust Repair

[hydronaut]

Finally got around to cleaning up the frame and giving it a coat of Corroseal and Fluid Film (working front to back) but found one spot that needs some attention, no issues anywhere else. Odd only one side but there was a bunch of crud caked up inside. There is a 1/2 drain hole in this spot and seems to have rusted around it. Cleaned out inside, sides and top are good.

I can weld half decent so no issues patching but what is the best way? Was planning on using 1/8 or 3/16 plate. Should I cut out and weld in a flush patch, patch overtop?

Thanks

 

[MM3846]

I would cut it out and weld a patch that wraps around the rail (Both sides and bottom). Then add a drain hole at the very bottom of the rail.

 

[hydronaut]

I would cut it out and weld a patch that wraps around the rail (Both sides and bottom). Then add a drain hole at the very bottom of the rail.

Appreciate the advice. I will cap the sides and bottom. Woukd you use 1/8 or 3/16?

Also would it be worth drilling some holes in the cap and plug weld on the sides and bottom in addition to the edges?

 

[MM3846]

Idk what the original frame gauge is, but I’d probably use 3/16.

plug welds for sure. Maybe one big one on each side.