Rust hole and small hole to the right





Seeking advice on how best to repair a small rust spot on a 2004 dodge ram 2500. The rust spot is pictured below. The teuck is a low mileage 67k and well taken care and mostly used for towing. While looking the truck over before planning to use it this summer. I noticed a spot on the insisde passenger frame that was bulged. Sure enough it was rusted out. So I knocked the remaining rust out so now you can see the whole im working with and a small whole towards the back. Overall the rest of the frame looks immaculate (see pics) and I can't find another spot that's rusted. I just wish I kept up with the undercoating over the years.

I can mig weld and use to as a side hustle but I never did truck frame repairs. For something like this should I 1. cut out a little bit more of the frame and butt weld a piece into it?
2. Should I overlap a piece of metal on top of the piece I butt welded in?
3.Given the rust is near the bottom angle of the frame should I weld in an angled piece that goes on the bottom of the frame and covers the top of the area with the holes? If so what gauge metal? For a case like this not really sure what's the best and proper way to repair it. Thanks for any advice I can provide more pics if needed.

 

Is there dirt or something collecting behind the hole??? Kinda strange that you just have that one spot....

Think I would cut out any rusted metal, and just lay a patch over it, call it a day. Wrapping it around the bottom of the frame certainly wouldn't hurt.

 

Yeah, looks really odd as the rest of the frame looks in very good shape to me.
I'd cut it out (using round edges to avoid problems due to "stress concentration"), then weld a piece over it and around the bottom as well. That should do the job quite good.

 

Thanks guys, it is odd for frame to have that hole at same time I am in rust belt. Truck is mainly used for towing and is garage kept but the road salt here in pa can be found sometimes in spring time (March April). I try to wash undercarriage as best I can but I just wish I kept up with the undercoating from when it was bought new.

I'm going to look for angle iron that goes over the hole area and across bottom. I'll weld around it. I feel that will give most strength and look better that way. Might do other side just to match and make me feel better. Then time to undercoat truck all over again.

Pics below are from recent weld job I did for an enclosed trailer jack. Thanks for input fellas!!

 

It rusted from the inside out. I'd get a good look everywhere else on the inside of the frame, usually it doesn't just happen in one spot. I don't think I would butt weld a patch on a frame tube. You might want to take it somewhere that does frame repairs and see what they recommend. When you're done repairing, clean out the frame and spay a liberal amount of fluid film (equivalent) into every nook and cranny so you wear our rather than rust out.