Question on Inner/Outer rocker design…

[AllGoNoShow]

I have a little rot in the channel near the edge of the floor right before the inner rocker turns down and meets the outer rocker. I’m going to be trying to address it without getting into the outer rocker, but I am curious if the outer rocker is spot welded to the inner where they overlap slightly (before the inner rocker turns down).

It looks like from some pictures I’ve seen of people replacing them, they throw a couple spot welds from the top of the outer rocker, in the door jamb area, where I would presume it is spot welded to the inner rocker, but I don’t know if this is stock or not. Just trying to get an idea of how I am going to do this. Truck is painted already and I don’t want to get into the outer rockers for that reason. (Picture attached)
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[May70]

If you watch this video I weld on a rocker the same way the factory does. Its probably easier to see how they go together. I have numerous other videos on rockers if you need more visual. https://www.youtube.com/watch?v=9VMt...omRestorations

You will have some trouble because that "shelf" or 'L' shape is right where there are spot welds. So you would need to drill out all the spot welds on the top of the outer rocker and separate the inner without damaging the outer. Possible but you would need to be very patient. Best route is to do a lot of grinding from the bottom just to get rid of the inner. I would almost try to just cut out that 'L' shape and make a new one. If you watch this video I did that. https://www.youtube.com/watch?v=4d6o...omRestorations

Here are a few factory assembly manual shots.
All 'X' marks are spot welds.
Colored diagram shows you the layers of where those panels meet.
Red = inner
Blue = outer
Yellow = weather stripping
Orange = sill plate

Let me know if you need some help.

[HO455]

Great reply May70.

[SkidmoreGarage]

Great information above, but I'll add some opinion. If you see rust in the inner rocker, the outer rocker will be rotten as well. Also, once you do the work to get the outer rocker off, you will be doing body work and paint. Now, if your outer rocker is in pretty good shape, I'd patch the rust spots and reuse it. The reproduction outer rockers are hit or miss in my experience.

[custom10nut]

Absolutely subscribed!Im about to fix my own rockers.

[May70]

I will add a note that based on the condition of the inner rocker it is highly likely that your lower A pillar has substantial rust which you won’t see until the outer is removed.

Your outer rocker is probably getting pretty thin with the level of rust through on the inner so it may be advisable to replace both. You would end up with a better product and know your pillars are good.

One alternative is to carefully remove the outer rocker by cutting out spot welds, with intentions of reusing it. That would be a difficult and time consuming process not to bend/cut the rocker up while removing it.

[SkidmoreGarage]

See above, more great info!

I want to add that repainting the outer rocker is really straightforward in the grand scheme of the total work. There are great edges for the paint masking.

[AllGoNoShow]

Thanks for the tips. For some odd reason, previous owner actually replaced the driver side outer rockers (without replacing the inner part which clearly had the above rot) and then also handed me an extra passenger rocker which he didn't replace.

I guess I have to decide how "right" I want to do this, This may be more of a repair and then keep the right way to do this (inner and outer rocker replacement) for the future.