Holes!

[Lippyp]

Finished removing the carpet from the truck yesterday and had a better poke around. I have a definite hole in the bottom of the passenger kick panel although whats inside seems solid. There are a series of small rust holes at the edge of the floor where the passenger rocker panel joins (just in that dipped section) The edge of the rocker panel that side where the door seal mounts has rusted off along most of its length although the front half looks like its been patched as it's just a plain seperate piece of newer steel without the little lip at the top. So it looks like I need to replace the rocker panel that side. The back of the rocker seems solid from underneath though. The dorr seal flange on the drivers side is just starting to hole although it's in much better shape than the passenger side as is the kick panel. I guess I should really do the pair at the same time rather than let the drivers one deteriorate any more. I also intend to pull the seat and gas tank, reseal all the seams after grinding the surface rust off and paint the whole thing with POR15 before the new carpet goes in.

I was thinking about ordering the rockers, inner rockers panels, and possibly the lower kick panel repair sections from GMC paul, having dealt with him in the past. Anyone used his rocker panels, do they fit well? I have to make sure I get all the panels I'm likely to need as being in the UK means it's takes some time to get stuff like this, as you have shipping times, customs hold ups etc.

This will be the first real bodywork I've done other than minor repairs involving large tubs of bondo on past old cars. I have a decent mig welder (sip migmate 150amp turbo) and can weld reasonably well, the kick panels will be carpeted so the odd lump won't be too noticeable! The big problem is all this rust has been caused by a leaking rain gutter so I've got to dig all the sealant out and reseal it before I do the repairs. I'm also going to have to find a bodyship with a paintbooth big to fit the thing in to paint the repairs as I don't have painting facilities.

Oh well, it was worse than I hoped but better than it could have been, at least the cab corners and floor are solid.