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is there a spray on material that will STOP the rusting process? if not...whats the best way to get a handle on it without having to tear the truck apart?
also...how do you find out how thick sheet metal you need to do patch replacements.
Maybe you could take a look at Zero Rust (zero-rust.com). I have started painting suspension parts with it and will do the frame as well. It's fairly cheap, people say it works well, and can be applied with brush, spray, etc. So far, pretty easy to work with.
In the past, I've always done frame restorations the old fashioned way, tearing the vehicle apart, wire wheeling the frame, welding in additional material if necessary, then prime and paint.
What I've found thats even better, is to wire wheel the frame, then prime and paint it with BED LINER. Same for floor pans top and bottom. The stuff is reasonably abusable, so salt, rock chips and the like, dont do any damage for many, many years.
You'll never really get to the top of the frame done correctly unless you take things off the frame, including the bed and the body, however.