Does anyone have experience with replacing the frame rails in the engine compartment? I have already made and replaced the rocker frame rails, floor pans, under-floor frame channels and ran these back to the rear cross supports, large parts of the firewall and foot box areas all from 14 gauge steel, as well as several inner fender patches under the battery and master cylinder areas. The next step would be to make and replace the forward frame rails and then reconnect to the foot box area and under-floor channels. This is a big job. Is this normal or do most people just cover these to reinforce them. My frame has several rust holes up near the radiator support and I pulled out a lot of rust with magnets, a vacuum, and compressed air so I am worried about how thin they have become. I know that it would take a lot longer to replace these rails verses killing the rust and covering them with a formed c-channel and maybe adding some gussets. I am also concerned about getting new rails back in the correct locations including the compression rod mounts.

Thanks for the suggestions

Charlie Osbourne (Zedd Findings) make replacements so at least you don't need to re-create them. They do not come with the TC rod pockets though. I've used them, they are wonderful. With what you've done already, I think you can handle it.

I do like the idea of an over-lay of fresh material, sounds easier and definitely stronger, but I worry about rust coming back underneath eventually if you're not VERY careful about rust removal and sealing.