Frame Rust above rear bump stops

[sealica]

I got a couple of rust holes in my frame where the extra layers of metal from the rear upper bump stops attach to the frame rail. I was preparing to paint the area, but decided to do the proper thing and tap it lightly with a hammer which resulted in the holes and a bunch of rust flakes that I vacuumed out. The rest of my frame until the front of the van appears really solid with no weak sections such as this, but I've ordered a borescope to take a look inside before I decide next steps ...

I'm wondering how feasible a proper frame repair would be in this location. I'm aware the correct way is to cut the old metal and replace, but wondering how that would interact with the layered metal of the bump stops. I suppose they could be removed and re-fabricated?

 

[TimB]

I recently found a hole in the same spot, just aft of the bump stop, except it was on the inside face of the rail (so not visible from the wheel arch side). I cut a rectangle of rusty steel out the side of the rail and welded nice, think plate in the hole. It looked to me like there is a strengthening insert inside the rail here (I think you can see part of it in your first photo). So the rail itself is double-walled at this point and this seemed to be the site of the rot on mine (rather than rust developing between the bump stop body and the outside of the rail). Quite common that something designed to strengthen a structure ends up weakening it when rust gets to work I've not got any plans to do a larger repair in future, just to keep an eye on the area and keep it coated inside and out with something that prevents further rusting.

 

[sk66]

I think it should be pretty straight forward... that's in between the leaf spring mounting points; it needs to be structurally sound.

 

[TieMyShoe]

If the rust has gone under the bump stop bracket the correct fix is to drill out the spot welds, remove the bracket, fab up a patch for the frame rail, cut the old rust out and weld in the patch. then weld the bracket back on over top. it sounds like a bunch of work,.. but its not actually to bad.. it more messy and annoying than it is hard.