At the risk of sounding like a complete moron (unfortunately not far from the truth), I wonder whether rusted frame rails can be replaced or repaired with "new" welded in pieces of steel? I'm no welder or metallurgist, but it just seems that grinding off the rust and coating it with POR 15 or something similar is kind of temporary and will have to be repeated annually. I'd like to figure out something I could have a welder or a body shop do that's permanent.

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I never go far without a little Big Star

1994 E500 199/Gray 82k
84 300D (Salty) Orient Red/Palomino 141k
88 300CE (Ersatzhammer) 904/Java 163k -- Turbo Technics twin turbo kit, AMG Gen I body kit, Sportline steering box and steering wheel, Sportline/Eibach /Bilstein Sport/500E suspension, Quaife LSD in 210 mm diff case, Silver Arrow brakes.
88 300CE Brabus 3.6 199 on Black 44k