Replacing Rocker panels.

[custom10nut]

On a scale of 1 to 10, how difficult is it to remove the old and install new Rocker panels?
My cab corners are solid as is the floor, so the rockers are the only piece that need replaced.
I’ve read before, that drilling out the spot welds, and the old should pop out.
Then the new is welded back in place. Is there body seam sealer where the panels meet?
Sounds easy but I’ve also seen and read about the misalignment horror stories.
That’s my fear
It’s been a while, but I’ve done body work, and can weld.
I just don’t want to create a mess by attempting something beyond my abilities.
Any tips/pointers/advice anyone can give me?

[Willowrun]

My advice is to try to save as much of the original metal as possible which typically means sectioning out only the metal that needs to be replaced out of the replacement panel. Use butt welds when doing this type of repair.

If the majority of the rocker is bad to the spot welds or around the top into the floor then probably just replace the whole thing. Cut out original spot welds with spot weld cutter.

Keep the doors on if at all possible and if you do replace the whole rocker use screws to hold it into place so you can check door gap alignment prior to welding. Check gaps often before burning it in for good.

I've never braced a cab for rockers but others have so can't say what's right there.

[Jason Banks]

Willowrun has given you excellent advice about saving as much original as possible. The reproduction rocker panels are not perfect. Back in the day if you got GM rockers they were a direct replacement and were shaped nearly 100% correct. If you can use the repro panels to cut pieces out of and section them in, you'll be better off.

I had to pie cut and section to get the reproduction to line up. Then I still ended up with some odd concavity in the door sill area on one side. That I ended up flattening out with filler.

Yes, you will need to seam seal along the edges in the door jamb to seal them up.

Post a picture of what you are working with?

[72c20customcamper]

Save as much of the original as possible . It can be more difficult but the end results are worth it . This is the truck I’m doing now the rockers weren’t too bad so I saved most of the original . Even though I’ve been doing body work since the 70s this guy showed me a lot of different techniques like cutting the butt weld as you go so the panel doesn’t warp .

https://m.youtube.com/watch?v=TCR_2TFL_e0

[HeavyHauler]

Originally Posted by 72c20customcamper

Save as much of the original as possible . It can be more difficult but the end results are worth it . This is the truck I’m doing now the rockers weren’t too bad so I saved most of the original . Even though I’ve been doing body work since the 70s this guy showed me a lot of different techniques like cutting the butt weld as you go so the panel doesn’t warp .

https://m.youtube.com/watch?v=TCR_2TFL_e0

Since you dont have access to the back side of that rocker panel did you just leave the other piece that was under it still inside the rocker. If you left the other piece inside the rocker it might make noise if sliding back and forth.

[72c20customcamper]

Originally Posted by HeavyHauler

Since you dont have access to the back side of that rocker panel did you just leave the other piece that was under it still inside the rocker. If you left the other piece inside the rocker it might make noise if sliding back and forth.

In the closeup you can see the gap as I welded and cut when I made the patch there was a only like a eighth of an inch overlap so really very little fell into the rocker . The cutoff I fished out through the hole in the front of the rocker with a magnet and needle nose pliers . There was also a hole on the inside rocker that needed fixing so I had access in two spots

[HeavyHauler]

Originally Posted by 72c20customcamper

In the closeup you can see the gap as I welded and cut when I made the patch there was a only like a eighth of an inch overlap so really very little fell into the rocker . The cutoff I fished out through the hole in the front of the rocker with a magnet and needle nose pliers . There was also a hole on the inside rocker that needed fixing so I had access in two spots

OK I get it now. The overlap was so thin that you almost cut thru it when you were doing the cut and butt welding. Very good with access to remove any extra! Nice!

[Louisvillekytruck]

Originally Posted by 72c20customcamper

In the closeup you can see the gap as I welded and cut when I made the patch there was a only like a eighth of an inch overlap so really very little fell into the rocker . The cutoff I fished out through the hole in the front of the rocker with a magnet and needle nose pliers . There was also a hole on the inside rocker that needed fixing so I had access in two spots

Looks great

[GASoline71]

All I can say is be prepared for more rust underneath than you originally thought. Rust never sleeps, so usually the inner rocker, lower "A" pillar and side panel need to be replaced too.

Gary

[custom10nut]

Originally Posted by GASoline71

All I can say is be prepared for more rust underneath than you originally thought. Rust never sleeps, so usually the inner rocker, lower "A" pillar and side panel need to be replaced too.

Gary

Absolutely.
Today I took a scraper to the Rockers today.
I pulled the sill plates and rubber seal to actually get a look at what needs replacing.
It’s actually not as much rust as I was expecting.
I was pleased with the condition of the floor panel and that I don have to repair the inner rockers.
Another thing I did today was to pull my tailgate off to see how much repair is needed on it.
Glad to find out that there’s only about a dozen little holes, none of them larger than a pencil eraser, and I can fill them with my MIG Welder.

[custom10nut]

Additional Question on patching my Rockers.
I want to Butt Weld the patches in, so that there’s minimal body work to finish them.
Is it best to measure out and cut the patch, then cut the rust are out to fit the patch?
I’ve got replacement Rockers that I’m going to use for patch material, so I won’t have to do any bending to get them to fit.

[72c20customcamper]

Originally Posted by custom10nut

Additional Question on patching my Rockers.
I want to Butt Weld the patches in, so that there’s minimal body work to finish them.
Is it best to measure out and cut the patch, then cut the rust are out to fit the patch?
I’ve got replacement Rockers that I’m going to use for patch material, so I won’t have to do any bending to get them to fit.

I cut the rust out first . Mostly because you really have no idea how bad the rust is till you start cutting . Nothing worse than going to put the new piece in and the weld burns through. And now your adding more patch .

You will have to do bending and tweaking on the patch panels they aren’t exact to the OEM panels

[custom10nut]

So, I tore into both sides today, to get to the built up rust and crap that collected in there.
Tomorrow, I’m going to mark off the area and start measuring the stuff to be cut out.
Another thing I did was grind out all the little Pinholes on the inside/lower panel of my tailgate.
I’m self-teaching myself to MIG Weld, and fill in the holes.
So far it’s going pretty well.
I figure by the time I get the tailgate done, I’ll be skilled enough to tackle the Rocker Panel patching.