Today when changing the oil, i noticed alittle rust on the right front frame rail( behind the wheel). So i poked at it know i got a dime size hole and noticed its double walled. Would it be safe to por15 the inside and weld a 1/4 piece of metal or will it be all right? The rest of the frame is solid but that one spot was bad.

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Would it be safe to por15 the inside and weld a 1/4 piece

Yes it's safe to weld to the frame. As you know prior to welding make sure all corrosion has been treated and cleaned. Your right on the money 1/4 plate works best on the frame.

They rot there because of the doubler. I plated mine in the same place. 3/16" (7 gauge) is more than adequate, actually. I used 1/4" because it was on hand. 1/8" would probably be sufficient since the frame is thinner than that.

Pressure wash what you can out of it while you have a hole poked in it. Let it dry and POR it. Plate it, paint it and call it done.

Thats a relief, i thought the truck might be doomed. I plan on having the frame sand blasted and coated with por15 this may. Thanks for the help guys