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Thanks for the input, the photo doesn’t look as bad as it is (at least for me). The spread was 1/2” to 3/4” in some places. Until i had my International frame crack in 4 places along the bottom flange I wouldn't of never even thought twice about rust between 2 frames. The spread on the International was just about the same as this. I have a steel wholesaler making me 2 new rails, my main concern was the fact that I heard around here they were failing double frames because of the spread. Reading the posts about this issue made it seem as if once the rust was removed that the rails would just align back into place without any gap. Heres some pictures of the International frame cracks due to the double frame rust.

Here are the pictures of the rust jacking before I removed the rails, note the spreading. After they were removed the rust was cleaned off, when the inner rails were off and were measured I realized that there would still be a decent sized gap between the inner/outer rails. Now Im wondering if there is a way to make them align again, or are new rails really needed?

Hey I know this is an old post but thought id ask as I'm going through this exact problem right now. Ive split the rails, the outer rails went back into place. However, when measuring the inner rails when removed I noticed that there will still be a gap when they are put back into place. Any thoughts or ideas as to what to do in this situation. Is there anyway to save these rails and have them align with no spreading with the outer rails?. Or do I need new inner rails? Thanks for the input(11 years later) haha