At Kinmel Campers, we often see how corrosion can compromise both the safety and performance of hard-working vehicles. One recent project involved a Toyota Hilux pickup that came to us with a severely corroded leaf spring hanger. This component plays a crucial role in supporting the suspension system, and when rust takes hold, it can put the entire structure at risk. Our team carried out a complete repair to restore strength, reliability, and road safety for the customer.
Identifying the Problem
The Hilux in question arrived showing obvious signs of corrosion underneath. Upon inspection, the leaf spring hanger—which secures the suspension leaf spring to the chassis—was heavily rusted, cracked, and no longer structurally sound. Rust damage in this area is quite common in older pickups, especially those exposed to wet, muddy, or salty road conditions. Left untreated, this issue can lead to suspension misalignment, poor handling, or even dangerous failure while driving.
Cutting Out the Rust
The first stage of the repair involved carefully cutting out the rotten metal. We removed the damaged section of the hanger and surrounding rusted areas to ensure a clean base. This step is crucial, as welding onto weakened metal would only create further problems down the line. With the corrosion completely cut away, we prepared the chassis for the installation of a new hanger bracket.
Welding in the Replacement Hanger
A brand-new replacement hanger bracket was fabricated and welded into place. We used high-strength welding techniques to guarantee the repair would be as durable as the original, if not stronger. During the process, our technicians double-checked the alignment of the leaf spring to ensure proper suspension geometry. This ensures the Hilux not only regains its strength but also maintains smooth handling and balance on the road.
Protecting Against Future Corrosion
After the welding work was complete, we treated the entire area with anti-corrosion protection. High-quality rust-proof coatings were applied to the repaired section and surrounding chassis to guard against moisture and road salt. This protective step is essential for vehicles like the Toyota Hilux pickup, which often face demanding environments, whether on worksites, farms, or rugged off-road trails.
Restoring Strength and Safety
With the new hanger bracket securely welded and treated, the suspension system was reassembled. The leaf spring sat firmly in its new mount, giving the Hilux back its stability and strength. The customer can now rely on their pickup knowing that the suspension is secure and corrosion has been dealt with properly.
Why Rust Repairs Are Essential for Pickups
Rust and corrosion are common issues on pickups and vans, particularly in high-stress areas like suspension mounts, sills, and chassis rails. Ignoring rust damage can quickly turn a small problem into a major safety hazard. At Kinmel Campers, we specialise in bodywork services, chassis welding, and rust repairs, ensuring that vehicles are safe, reliable, and roadworthy for years to come.
Book Your Rust Repair at Kinmel Campers
If your vehicle is suffering from corrosion—whether it’s a leaf spring hanger repair on a Toyota Hilux pickup or rust patches on a campervan—we’re here to help. Our experienced team can handle everything from small welding jobs to complete structural restorations.
👉 Contact us today at Kinmel Campers to book your rust repair or inspection.
