Frame repair, or frame swap options?

[Doorgoo]

So, my 1989 325ix is an absolute tank despite pretty mild rust. Drivetrain was entirely refreshed 40k miles ago. Just put in a rebuilt steering rack, new brake lines, bought a new gas tank, have lowering springs and new CABs, and guess what was found this time for inspection? The rust is worse than what could be seen, I have frame rot. So, what's my options? I've already posted looking for a shell but would it be worth trying to patch up? Can I get new frame rails? Has anyone just put a new frame on before? Or do I cut my losses and run? I was hoping to drive her while I was working on my head swap car but, well gotta figure this car out first. Thanks all.

[TobyB]

For starters, you don't have a frame. So we're going to be a little less help right off the bat,
unless someone made an unholy monster truck out of a K5 Blazer frame and an E30 body...

What you have, most likely, is rust perforation, which when I lived in PA, had to be "smaller than a quarter".
Or you fail inspection.
The hole can be anywhere, which doesn't make much sense, but there it is.

The fix is metal repair. The E30 shell can be cut apart and rewelded in all sorts
of ways, but the LOCATION of the rust makes a big difference in the COST.
For example, rust in your outer rockers isn't too bad- cut away the old, weld on new.
But rust in your INNER rockers is a lot harder, as the outers have to come off,
and then lots of things have to be cut off the existing inners, and then re- attached.
So, pulling numbers out of the air, if an outer rocker costs $500 to fix, the inner will be
$1500, mostly in labor.

The front 'frame rails' can be replaced, too, and it's not too hard. The rear subframe
mounts, conversely, are quite difficult.

And when I lived in PA, I passed inspection multiple times by using pop rivets,
fiberglass, and undercoat. Because I was a poor- ass college student with an old Chevy.

Pictures would help a lot.

t

[Doorgoo]

Well, I dropped it off so I'll get pics soon but from what is being described its the floor pan near the jacking points along with "frame rail" near there. My old man talked to the guy while I was at work and says he thinks it can have a patch welded in. Idk. He made it sound really bad but hopefully it's a "simple" repair. When I get pics I'll be sure to post them.

[ThatOneEuroE30]

unless someone made an unholy monster truck out of a K5 Blazer frame and an E30 body...


t

Rutledge Wood