How much is too much frame rust?

[KDP]

Hello, new to the forum and looking at purchasing a used Airstream in the near future. We recently looked at a 2007 Classic 27FBR and it was in excellent condition other than some concerns with rust on the frame behind the exposed areas behind the tires and the cross beams. Hoping to see if this is just surface rust that can be remedied and ensure years of good use ahead or if it would require a more major repair. I plan on reaching out to Airstream Service in Jackson Center to see if they are able to diagnose the job via the photos. Any experience with this kind of repair and cost would be greatly appreciated!

[Redbarron55]

It looks like there is extensive corrosion, including exfoliated corrosion where metal is coming off in flakes, indicating that the corrosion has penetrated into the metal.

My 1985 had some light surface rust without pitting and I cleaned it, treated it with a phosphate wash and repainted with heavy duty Rustoleum.

While I was replacing some bad spots in the floor at the rear there was also some light surface rust there which was treated as well. The original paint was still OK everyplace I could see through the various repair holes.

The pictures show relatively deep pitting/ I would be concerned as this look to be in the area where the axle(s) are located.

I think that the areas where there are large flakes should be examined carefully and every area you can get to should be wire brushed so that the extent of the damage can be determined.

This is a lot of rust for a trailer that is a 2007 and a lot more than my 1985 Sovereign. This shows two things to me, one is that the protective paint did not do it's job very well and the other is that this trailer lived in a very corrosive atmosphere, perhaps near or on the beach.

I think that the extent of the rust would warrant further examination for bending, cracks and other deterioration.

Contacting the Mother Ship might be a wise step, but you are just looking you might want to look further or get a very good discount on condition of the frame. Repair, if necessary would be relatively high and replacement of the frame near the cost of a new trailer, quite possibly. I believe that the labor cost runs about $140 an hour and to replace the frame I believe that the entire interior would have to be removed and the you have floor repair or replacement and a new frame, if the frames can still be purchased 18 years later.

[sfranklin]

I've had Aistream trailers for about 23 +/- years, one I owned for most of that time and my frame never even came close to looking like that. My daily driver, yup, mostly because I live in the rust belt and we use lots of salt in winter. To me, that screams towed in winter, in salt and never maintained.

It'd be a hard walk or a sprint away from it if it were me. As one pointed out on another thread, if one area is not cared for, how many other areas haven't been cared for that are not as obvious...for example, leak testing and resealing of the exterior of the trailer.....with all that is out there, keep looking!

[KDP]

Thank you for the insights! After talking to Airstream Service Center and sending them these photos and a few others, it looks like there is a section of metal that sticks down below the frame that the axles attach to and not the frame itself, this is where most of the heavier rusted areas are and they said it was not uncommon to see this on a unit this old, though they would recommend grinding it off and painting the next time the axles get switched out. Worse case, since the areas are below the actual frame, certain areas could be swapped out.