Apart from the engine and its related components, the car frame is another essential part of your car you need to pay attention to.
The car frame is made from steel and iron and provides a support system for the car’s entire body. Due to its material composition, the car frame can be subject to rusting. So, here goes the big question: “Is it safe to drive a car with a rusted frame?”
First and foremost, let’s understand what rusting is. Rusting happens when the car’s frame is exposed to water, as in winter in the presence of air, leading to oxidation.
The result of this process is that the metallic frame begins to eat up gradually. If left unattended, the rust can depreciate the overall value of the vehicle.
What is Frame Rust?
Frame rust is corrosion that forms on the car’s frame. It happens when iron, air and water come together. This mix can lead to metal degradation over time.
Surface rust and deep or structural rust are the two types of frame rust. Surface rust only affects the top layer of your car’s frame. Structural rust goes deeper and makes holes in the metal parts it hits.
In fact, Toyota says a 10mm hole from this kind of rust makes a car unsafe.
Why is Frame Rust Bad For Your Car?
Frame rust can harm your car in many ways. It is a sign of corrosion or oxidation on the metal parts of your car. This happens when air and water mix on bare metal.
One big problem with frame rust is safety risks. The frame of a car gives it strength. Rust can make the frame weak. If not treated, holes may form in the frame over time. Driving a rusty car can be risky.
Another bad part about rust is how it looks. People like their cars to look good! Rust spots do not look good at all! Plus, if you want to sell your car, rust will bring down its price.
Lastly, rust messes up how your car works too! For instance, if there’s rust on wheel parts or brake parts, they may not work right anymore.
Different Types of Frame Rust
There are two types of frame rust. These are surface rust and structural rust. Surface rust is what you can see on the top layer of your car’s body. It looks like light brown or faint red spots on the metal parts.
Even though it may not look good, this type of rust does not hurt your car’s health. On the other hand, structural rust is a bigger problem for cars. This kind of rust eats away at important parts under your car like its frame and underbody.
It can change the strength of these parts over time, which could put you in real danger if these pieces were to break while driving.
Once surface rust starts to eat into deeper layers, it becomes structural rust. We must keep an eye out for both types since they damage our vehicle differently but surely cause harm sooner or later.
Causes of Frame Rust
Rust forms when iron or steel reacts with oxygen and moisture, leading to corrosion. Several factors contribute to the rusting of a vehicle’s frame:
- Environmental Exposure: Vehicles in regions with harsh winters, where roads are salted to prevent ice, are particularly susceptible. Salt accelerates the rusting process by lowering the metal’s resistance to corrosion.
- Age and Wear: Older vehicles are more likely to develop rust, especially if they haven’t been appropriately maintained. Over time, paint and protective coatings wear off, exposing the metal underneath.
- Driving Conditions: Frequent driving on dirt or gravel roads can chip away protective coatings, making the frame more vulnerable to rust.
- Neglect: Lack of regular maintenance and inspections can allow rust to go unnoticed until it has caused significant damage.
7 Hidden Dangers of a Rusted Car Frame
#1. Rusted Car Frames May Snap in an Accident.
Unlike auto body rust, frame rust compromises the entire safety and structure of your vehicle. The rust on a car or truck frame is often unnoticed, slowly eroding away at the metals that hold the vehicle together.
While this may appear the same as always, just rusted, it can actually go much deeper than surface level.
When in an auto accident, a rusted car frame can snap, since the metal holding it together has been eroded. This can lead to dangerous circumstances that can result in deadly injuries. Your frame helps hold the car together – don’t let it go unnoticed.
#2. Rusted Car Frames May Sag During Normal Driving Conditions.
Even if you’re not in an accident, rusted car frames can snap or sag during normal driving conditions. Because a rusted car frame loses its structural integrity, this puts it at risk for damage during normal driving conditions.
If you hit a pothole, Knick a curve, or encounter rumble strips on a roadway under construction, this can be enough of a jostle to the compromised frame for it to sag or snap.
Without rusted frame repairs, your vehicle’s safety level is dramatically lowered and puts all passengers at risk during normal road trips and commutes.
#3. Rust Exposure Can Damage the Engine.
A rusted car frame doesn’t only compromise the framework of your vehicle. A rusted frame can indicate rust in more places under your vehicle.
When rust works its way up the frame and the underside of the car, it can reach the engine. A rusted engine, or engine components, can lead to big repairs and dangerous breakdowns.
A total engine replacement or rebuild can cost anywhere from $2,000 to $5,000. Avoid the unexpected costs and ensure your car frame is free of rust and other damages.
#4. Electrical Components May Be Unprotected.
If rust has worked its way to your engine, this means it has eroded away the protective framework that keeps electrical components away from the elements.
When your electrical systems are exposed to rain, snow, salt, and other moisture, this can have dangerous consequences.
For both newer cars and older vehicles, when the electric of your car is damaged, you can lose access to multiple safety features.
This can affect power steering, the battery, lights, and more. Plus, electrical repairs for cars and trucks can be up to $1500 or more for an entire vehicle rewire.
If your frame is rusted, more could be damaged than just the metal – get an inspection today for frame rust repairs and get ahead of the problem.
#5. Leaks, Drips, and Other Vehicle Concerns.
Just like your electrical components being damaged, a rusted frame that works itself deeper under the vehicle can also damage pipes, wires, lines, and more. This can lead to oil leaks, coolant drips, missing power steering fluid, and more.
If you notice spots of oil or other liquids staining the driveway under your car, consider the possibility of vehicle frame rust that has worked its way through your car. Schedule a vehicle inspection to prevent unexpected breakdowns or accidents.
#6. Risking Damage to Tires and Wheels.
Most frame rust for trucks and cars is hidden and more often than not it is in the wheel wells.
When the frame around your wheels and tires rust, this can compromise the safety of your vehicle. A small accident or harsh roadway could cause the vehicle to sag onto the wheel well.
Avoid catastrophes and invest in frame rust repairs ASAP to prevent damage to tires, wheels, and the entire structure of your vehicle.
#7. Faster Wear and Tear On Normal Components.
Even if your frame rust repair isn’t compromising the structure of your vehicle yet, it is leading to exposure to damage to other parts of your vehicle. This can be more exposure to rain, snow, salted roads, puddles, and more.
Any part of your vehicle that has been damaged by rust can lead to unexpected repairs and expensive costs. Don’t ever let the safety of your vehicle lapse.
Is It Safe To Drive A Car With A Rusted Frame?
So, you are wondering, “how much rust is too much on a car?” The answer is not far-fetched. First things first, you should understand there is nothing like ordinary rusting.
However, when you start noticing the boxed area of your car frame is beginning to peel off, that should serve as a red flag for you to take urgent action.
Also, when you observe holes all around your car frame, it is time for you to worry about the frame rust.
The presence of holes means the integrity of your car frame is compromised. At this point, it may not be advisable to take out your car for a drive, regardless of the distance you are traveling.
The frame creates a support system for the entire parts and accessories of the car. So, when you start seeing excessive rust on the car frame, it implies that the support it gives to the entire car body would be compromised.
So, what happens if a frame breaks while driving? Well, your car would not necessarily split into two halves as filmed in movies.
The rust, however, can weaken a part of the car. The rust can further lead to a car part falling off during motion, which could look weird. Yet, the vehicle would not completely break down into pieces on the road.
Having used your car for quite some time and you are ready to sell it off, and then you ask yourself, “Is it illegal to sell a car with a rusted frame?” In most states in the US, it is not necessarily illegal for a car dealer to sell a car with a rusted frame.
However, they must reveal this sensitive information in a document. If there is no written document stating the weakened car frame, the buyer can sue the car dealer for hiding such information.
Depending on the nature and severity of rust your car is exposed to, you can take your vehicle for a rusted frame repair to an expert auto mechanic.
The average rusted car frame repair cost can range between $1,500 and above. This high cost is a factor of the stressful labor, which is also time-consuming.
While you may equally opt to repair the lower part of your car, the underground rust repair cost is not too high. You could budget between $110 and $175. This cost covers both the cost of materials and the service of a professional mechanic.
Your auto mechanic may want to use a different method to correct the rust. He might either sandpaper the rust; apply paint and a lasting coating finish to properly bond the elements.
He can also replace the whole panel if the rust will be eating deeper during the sandpapering process.
Here is the juicy part. Cars with rust problems get rusted when they come in contact with salt water and air.
Usually, cars having such issues reduce the resale value of the automobile. So, when you want to purchase your next vehicle, you should avoid certain cars with rust problems.
How to Check a Rusted Car Frame
Steps for Inspecting a Rusted Car Frame:
- Complete a Visual Inspection: Inspect the frame for surface rust. Surface rust does not always mean there is an issue with the frame if it is sturdy enough.
- Check for Missing or Weak Parts of the Frame: Look for missing parts of the frame, like the missing upper section from the C channel in the picture below. Missing pieces and sections that are weak and can be easily bended are signs of a frame in bad condition.
- Tap the Frame with a Hammer to Test Sturdiness: If you come across a part of the frame that looks soft but you are unsure of its sturdiness, try tapping it with a hammer. A frame weak enough to tap holes through is soft enough to fail. If you tap the hammer and the frame remains firm, it is a sign of a frame in good condition.
- Look for Loose, Torn, or Corroded Brackets: Look for torn and loose brackets that are not longer able to bolt to the frame and are too corroded to be stable.
- Check Both Sides of the Frame Thoroughly: Inspect both sides of the frame thoroughly. A frame fine on one side but not on the other can still strain the soft side when lifted.
- Look for Stress Cracking: Check for stress cracking, which is a very bad sign. Stress cracking is worse than tapping holes into soft spots, because it is a sign there was enough stress to break the frame. Reinforcing the crack like in the picture below only sends the stress to other parts of the frame.
- Check for Holes in the Frame: Holes in the frame are also a sign of a frame in weak condition.
Not all of these signs indicate there is a problem with the frame, but at the least they indicate that the frame is beginning to wear. If multiple parts of the frame are in bad condition and unstable, it’s safe to say the frame is unsafe to work under.
How To Clean Rust on Vehicle Frame
Unfortunately, vehicle frames tend to rust over time. From time to time, you should check your frame for rust because it is more than just an aesthetic look.
You can clean rust on your frame only if it’s surface rust. If the rust is so bad that parts of your frame are missing, you should take your vehicle to the repair shop and fix it there.
Here is how to clean up a rusty frame on a budget.
#1. Wash your vehicle.
First, go ahead and wash your vehicle. You need the frame to be free of debris and dirt so you can really see which parts are rusted.
It’s best if you wash your car at home and let it dry. You can also spray some degreaser to help you remove any oil that could be on the frame.
#2. Identify the rusty areas.
Get underneath the vehicle and inspect the frame for rust. Check every part of the frame with a flashlight and try not to miss any part. Once you find the rusty parts, mark them with tape so it’s easy for you to find them later on.
Again, you can only clean the surface rust. If your frame is so rusty that parts are falling off, you should take your vehicle to the mechanic shop. Hit the rusty areas with a ball-peen hammer to see the condition of the rust.
#3. Remove any parts that are in the way.
If some of the parts are in your way of getting to the rust, remove them. If the rust is near some electronics or around the engine, mask out the area with tape and paper to prevent any overspray. Also, make sure that the engine is cold.
#4. Grind off the rust.
You can either do this manually or with a heavy-duty air-powered surface sander. Personally, this is too much work to do with sandpaper so I use power tools.
Start with 80 – 120 grit and then do the second hand with 220 grit. If needed, use 320 as a finishing touch. You should stop once the bare metal is exposed.
#5. Wipe the working area.
Give the working area a good wipe-down with a wax and grease remover. You can use any towel as long as it is clean. This will remove any contaminants such as dust or grease left behind.
#6. Spray with rust converter.
Spray the rust converter directly on the rusted parts so it will remove any rust left and your new finish will have a longer life.
When using a product such as this, always read the instructions so you know exactly what the product requires. Some rust converters are a liquid that can be applied and washed off.
#7. Paint the frame.
After a couple of hours of drying the rust converter, the frame can be finished with paint. For paint, I always use farm equipment to implement paint. If you have a leftover, you can use this paint on utility trailers, fuel tanks, mower decks, and other yard equipment.
Make sure the paint is dry before applying another hand. I usually leave the car couple of days so the paint can really dry before driving it.
#8. Re-install any parts that you removed.
If you removed any parts during this process, reinstall them and you are good to go.
Preventing Frame Rust
Preventing rust from forming in the first place is the best way to protect your vehicle:
- Regular Cleaning: Wash your vehicle regularly, especially the undercarriage, to remove salt and grime that can promote rust.
- Protective Coatings: Applying rust-proofing treatments and protective coatings can significantly extend the life of your frame.
- Routine Inspections: Regularly inspect your vehicle for signs of rust, particularly in areas prone to corrosion.
- Garaging: Keep your vehicle in a garage to protect it from the elements.
How Much Frame Rust Repairs Cost?
Depending on the size of the rust damage, the year make model of your car or truck, and what other damage has been caused, frame rust repairs can cost anywhere from $2,000 to $5,000.
In extreme cases, a total frame replacement can be up to $10,000 for most vehicles. To get an exact quote on frame rust repairs near you, contact an auto shop near you. The earlier you catch the damages, the faster repairs will go and the more affordable they will be.
You can help to avoid the unexpected costs of engine damage, electrical damage, and more by staying on top of vehicle maintenance and inspections.
FAQs.
Q: How long will a rusted frame last?
Ordinarily, if a good automobile fixes a rusted frame correctly, it should take a minimum of five years before developing a similar issue.
Another factor that may determine the longevity of a rusted frame is the nature of the environment where cars constantly ply. A water-filled road can hamper the coating finish done on the affected part.
The weather condition can equally affect the rust in cars. For instance, when it gets cold during winter, and your car gets exposed to the element alongside salt content, that can start your car’s rust.
Q: Can you drive a car with a rusted frame?
Considering the impending damage that can accompany a rusted frame, it is not advisable to drive such a car since rust is a type of corrosion that gradually eats the structure, causing the metallic frame to become flaky powder.
Over time as the rust eats deep, the structural quality of your car frame automatically reduces.
If you force your way to drive such a car, some of its parts can end up falling during motion. In a nutshell, excessive rusting will negatively impact the performance of your vehicle.
Q: Will insurance cover a rusted frame?
Most Insurance companies do not give compensation on a rusted frame. The reason is not far-fetched. Rusting, as earlier discussed, is a phenomenon that occurs from wear and tear, as the structure gets in contact with saltwater and air.
However, standard insurance policies do not include wear and tear because it is a scheduled event where the owner should have made proper provisions.
Rather than looking after rust and mechanical failures, car insurance companies only compensate for only unexpected events such as head-on collision with another car, third-party compensation, and other related incidents.
Q: When should I worry about frame rust?
When you notice excessive rust on your car frame up to a point where several holes are beginning to appear, it is high time you stop driving your car around. The gaps in your car frame imply that the structural integrity of your car frame had drastically diminished.
When you drive with an excessive rusted car frame, the police can stop you and order your car to be towed off the road. As a result, it is essential you determine the nature of rust your car frame may be experiencing at a time.
The rust might be cosmetic, or structural, or hidden. Any of the types of rusts need the urgent attention of your car mechanic.
A panel beater can equally help you confirm the nature of rust. You need to attend to rust because it spreads over time and can affect other unaffected parts.
Q: Should I buy a car with rust underneath?
The majority of car rust problems occur underneath the car and its related components. Underneath rusting is the most common because the car parts under the vehicle come in direct contact with salt water and air, leading to corrosion.
Car parts without rust ensure the durability of the car’s structure and will guarantee the lasting performance of the same. As such, it is advisable to call your mechanic’s attention to determine the nature of rust beneath a car before you purchase it.
Your professional auto mechanic will be able to tell whether the rust is minimal or risky that it would cost a fortune to get it fixed.
Q: Is frame rust repairable?
If you want to determine if a rusted frame is repairable, your panel-beater will have to confirm the severity of the rust.
If the rusted frame is localized, you can remove the rust by using sandpaper on the affected part, introduce rust treatment, paint and apply coating finish. This process kills the rusting and keeps it from spreading.
However, if the rust has started to develop holes on the frame, Your auto mechanic will have to cut away the affected part and replace it with a new structure. Apply paint and coating finish.
If you don’t mind, you can repair cosmetic rust by yourself by simply allocating quality time and be ready to work dirty as you apply grease and paint. It is as simple as that!
Q: How dangerous is a rusted subframe?
Your car frame rust should be a significant concern to you. When the rust is much, it reduces the integrity of your car’s structure. As a result, parts of the car could pull off and snap off while driving on the road.
Since the integrity of the car’s structure is compromised, the vehicle may not provide adequate protection during a collision with another car on the road.
Although you might drive with a bent car frame if it still aligns well, a collision with an oncoming vehicle can spell doom for you. It is better for you to properly fix the damage than to endanger your life and the lives of your passengers.
Q: Can you fix rust under a car?
Absolutely yes! The sharpest of swords will get rusted if placed in saltwater. As earlier pointed out, rust can be caused when you expose your car to saltwater and air. However, it can be fixed so long the severity is not so catastrophic.
Your mechanic can sand off the mildest rust; apply paint and a coating finish to prevent the rusting from spreading.
However, if the rust has eaten too deep, your auto mechanic should get a whole part to replace the affected region.
Final Words
The car frame can rust when exposed to saltwater and air, leading to a gradual eating away of the car frame. Yeah, you would ask “Is it safe to drive a car with a rusted frame?” The answer is no.
This is because the quality of the frame reduces as it rust over time, which can further endanger your life and that of your passengers.
To reduce rust, it is crucial you regularly wash your car, avoid muddy roads, inspect your vehicle more often, maintain your car’s paintwork.
If you reside in a humid area, you must apply an anti-rust coating regularly to save yourself from spending so much on recovering a rusted frame.