Any Tips on replacing rusted outer Rocker Panels?? - The 1947 - Present Chevrolet & GMC Truck Message Board Network

kxnomore · 01-26-2007, 12:28 AM

Hey guys,

I just got my new outer rocker panels from LMC today, and was wondering if anyone has any tips on the best way to change them out. You can see that mine are pretty bad.

What's the best way to cut out the rusted parts and how far do you cut out the old one? How much should the new one overlap what's left?

Thanks!!

short69 · 01-26-2007, 12:35 AM

I think the Classic Trucks magazine website has a tech article on this. One thing that I remember is that they say you should drill out the spot welds instead of cuttting the rockers out. I don't really know what the best method is cuz I've never done it myself.

ks147j111928 · 01-26-2007, 12:55 AM

I replaced my driver's side with an LMC rocker a while ago, here's some pics. The front end needed some minor modification though. Not a big deal. Also, if you're doing the cab corners... do those first. The front edge overlaps/tucks behind the rocker; I am kinda screwed for now... Sand off the paint to find and drill out the spot welds, that'll make it easier to remove. Plus you'll have the original metal to weld the new metal to. I just hacked it all out with a Sawzall and then took care of the spot welds. I guess you could remove it all at once, break out the chisel and hammer!

Before, note the ability to see through the rocker. Look familiar?
Name: rocker1.JPG
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Here's the thing gone. Metal edges are sharp... watch out.
Name: rocker2.JPG
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I also did the rear outer floor panel but should have done the front at the same time. Duh...
Name: rocker3.JPG
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Size: 35.9 KB

So yeah, there you go, I guess. Just be sure to measure the hell out of everything and get pictures if you can. Everyone loves pictures!

kxnomore · 01-26-2007, 01:01 AM

Nice work KS. How much did you weld the new one in. It looks like you laid down partial beads down the main span, but completely welded the ends?

Aarons72s · 01-26-2007, 01:48 AM

I cut the bulk out but stay away from the front and rear cab corners and inner rocker panel. I then either drill the spot welds out or use a air chisel, depending on my mood and where I am working at. Also I dont weld rockers back in. I bedliner the crap out of both the inner rocker and the back side of the new rocker and drill new drain holes. I then glue and rivit them on. Solving the rust roblem once and for all. Also check the outer edge of the rocker with a straight edge, the lip rigt under the outter edge of the door. Alot of the rockers lately are warped and not straight fron to back.

RustyParts · 01-26-2007, 11:34 AM

What Spot Welds???

timcos · 01-26-2007, 12:58 PM

I recommend ebfabman's replacement video. it is $100 and worth every penny.

www.ebfabman.com

Before I bought mine I wished it were cheaper (most expensive single DVD I ever bought)...But...after watching the 3 DVDs that some...I am telling you it will have saved me untold dollars (more than the price of the DVD), cuts scrapes, bruises and generally swearing like a sailor.

Also...

http://www.67-72chevytrucks.com/vboa...ghlight=rocker

Tim

krue · 01-26-2007, 01:47 PM

For rockers it shows what you need to do (plus it shows techniques to use for any patch panel). It's not as polished as some videos but it is informative.

kxnomore · 01-26-2007, 01:56 PM

The classic trucks site was good too. How did you guys locate the spot welds when drilling them out? I looked around but they seem very tough to locate.

rophle1 · 01-26-2007, 02:39 PM

Can bodywork beginners like me get anything useful out of these videos, or do you already need to be skilled at fabrication?

timcos · 01-26-2007, 03:25 PM

Quote:

Originally Posted by kxnomore

The classic trucks site was good too. How did you guys locate the spot welds when drilling them out? I looked around but they seem very tough to locate.

The assembly manual will show you the assembly spot welds.

Quote:

Originally Posted by rophle1

Can bodywork beginners like me get anything useful out of these videos, or do you already need to be skilled at fabrication?

I am not a fabricator nor am I a body man. I got a ton out of them and feel pretty confident this spring to do my rockers, kick panels and dab corners.

Tim

68shortstep · 01-26-2007, 08:16 PM

Quote:

Originally Posted by RustyParts

What Spot Welds???

"Yabba-Dabba-Doooooo"

ks147j111928 · 01-26-2007, 10:15 PM

KX-I re-spot welded on the ends and skip welded across the floor panel. Don't you hate when metal warps towards the end of a long panel? I used some Corroless primer from Eastwood then 3M undercoated the insides for rust prevention. Hope it works... at least until I sell it someday??

kxnomore · 01-26-2007, 10:20 PM

Thanks KS. My only issue now is finding the spot welds to drill them out. If I can't find them then the framer's best friend (sawzall) is going to make an appearance! I'm going for it tomorrow and will post pics of the progress...

*rage'nrat638* · 01-26-2007, 10:42 PM

heres a few of my rust job.. my 19 year old son @ the time, did mine

kxnomore · 01-28-2007, 01:21 AM

All right, here's an update. It took lots of drilling, peeling, and chiseling, but the rocker panels are free at last!!! By the amount of spot welds you would think they built these trucks to last or something!

Just my luck though that the rust didn't stop at the rocker panel. It extends into the floor and even up the kick panels.

I have some thoughts about grinding out the rust that's left and fiberglass repair over the holes??? After placing the new rocker panels, of course.

Anyone delved into this type of never ending rust?? The rest of the cab seems ok. The supports and all the middle part of the floor is great. Any ideas?

Aarons72s · 01-28-2007, 02:39 AM

Yes i have seen alot worse! I ended up replacing almost 75% of my floor and have did a outter floor replacement on a 67 to. Unless you get rid of all the rust and treat the metal and you fiberglass over it it will just come back to hunt you. Can you get me a pick of your kick panel so I can help you more? how is your front lower cab corner, the one with the tab that holds the fender on? Can I get a pic of that to? Looks like you will need a front floor pan, kick panel and front cab corner from what you are saying. You may also want to check the front cab support to. My green and white is starting to look like that and is going to need the cab support to.

prostreet1967 · 01-28-2007, 07:32 PM

the dummy that did mine put the rockers on top of the old ones then my door wouldnt shut so i dont think i can get to the spot welds

shifty · 01-28-2007, 09:42 PM

I'd suggest buying EbFabMan's video: http://www.ebfabman.com/

It will give you a reference video telling you all the tricks and tips to do it. I mean, you're already neck deep, but ....

Green 1959 · 04-14-2016, 01:04 AM

Quote:

Originally Posted by RustyParts

What Spot Welds???

Lol excellent

Lanman1972 · 04-14-2016, 08:00 AM

I read through a bunch of build threads, you tube and did a search for Rocker Panel on this site. Gain as much knowledge as you can. Make sure to fit/align the Doors and Gaps before final welding.

Orange Crate · 04-14-2016, 02:28 PM

X2 ^^^^^^^^ Make sure you hang your doors and check for fit and gaps BEFORE you weld. You will be good at all this when you move over to do the other side!

5567Cruiser · 04-14-2016, 06:42 PM

I found some NOS GM rocker panels from a friend that bought them about 20 years ago and when you use OEM panels they fit perfectly with no problems with doors and line up. The factory assembly manual is a great help for locating the spot welds on the old panels and I remember 37 of them and I used a spot weld drill by Eastwood that worked very well.

sick_46 · 06-30-2016, 03:08 PM

My drivers side rocker panel is rusted all the way up into the floor. If I buy the drivers floor pan do I need the inner rocker panel also or is that part of the pan?

**geunther** · 06-30-2016, 03:12 PM

Inner is part of the floor.

01-26-2007, 12:28 AM	#1
kxnomore Registered User Join Date: Dec 2006 Location: CA Posts: 331	Any Tips on replacing rusted outer Rocker Panels?? Hey guys, I just got my new outer rocker panels from LMC today, and was wondering if anyone has any tips on the best way to change them out. You can see that mine are pretty bad. What's the best way to cut out the rusted parts and how far do you cut out the old one? How much should the new one overlap what's left? Thanks!! Attached Images

01-26-2007, 12:35 AM	#2
short69 Registered User Join Date: Oct 2006 Location: las vegas Posts: 88	Re: Any Tips on replacing rusted outer Rocker Panels?? I think the Classic Trucks magazine website has a tech article on this. One thing that I remember is that they say you should drill out the spot welds instead of cuttting the rockers out. I don't really know what the best method is cuz I've never done it myself. __________________ 69 shorty w/ 67 front clip

01-26-2007, 12:55 AM	#3
ks147j111928 ASE Certified Spoon Operator Join Date: Oct 2006 Location: Colorado Springs, CO Posts: 157	Re: Any Tips on replacing rusted outer Rocker Panels?? I replaced my driver's side with an LMC rocker a while ago, here's some pics. The front end needed some minor modification though. Not a big deal. Also, if you're doing the cab corners... do those first. The front edge overlaps/tucks behind the rocker; I am kinda screwed for now... Sand off the paint to find and drill out the spot welds, that'll make it easier to remove. Plus you'll have the original metal to weld the new metal to. I just hacked it all out with a Sawzall and then took care of the spot welds. I guess you could remove it all at once, break out the chisel and hammer! Before, note the ability to see through the rocker. Look familiar? Here's the thing gone. Metal edges are sharp... watch out. I also did the rear outer floor panel but should have done the front at the same time. Duh... So yeah, there you go, I guess. Just be sure to measure the hell out of everything and get pictures if you can. Everyone loves pictures! __________________ My six is bigger than your eight 67 K20 292 +.060" SM465 NP203 3.73s 86 4Runner, the daily on 31s 85 4Runner, the wheeler on 38s 92 x-cab truggy project for 2017... tons and 42s and V8 power

01-26-2007, 01:01 AM	#4
kxnomore Registered User Join Date: Dec 2006 Location: CA Posts: 331	Re: Any Tips on replacing rusted outer Rocker Panels?? Nice work KS. How much did you weld the new one in. It looks like you laid down partial beads down the main span, but completely welded the ends?

01-26-2007, 01:48 AM	#5
Aarons72s Registered User Join Date: Apr 2006 Location: oklahoma Posts: 10,669	Re: Any Tips on replacing rusted outer Rocker Panels?? I cut the bulk out but stay away from the front and rear cab corners and inner rocker panel. I then either drill the spot welds out or use a air chisel, depending on my mood and where I am working at. Also I dont weld rockers back in. I bedliner the crap out of both the inner rocker and the back side of the new rocker and drill new drain holes. I then glue and rivit them on. Solving the rust roblem once and for all. Also check the outer edge of the rocker with a straight edge, the lip rigt under the outter edge of the door. Alot of the rockers lately are warped and not straight fron to back. Last edited by Aarons72s; 01-26-2007 at 01:51 AM.

01-26-2007, 11:34 AM	#6
RustyParts Registered User Join Date: May 2006 Location: Wyman, Kentucky Posts: 403	Re: Any Tips on replacing rusted outer Rocker Panels?? What Spot Welds??? Attached Images

01-26-2007, 12:58 PM	#7
timcos Chief Honcho In Charge Join Date: Aug 2006 Location: Bentonville AR Posts: 970	Re: Any Tips on replacing rusted outer Rocker Panels?? I recommend ebfabman's replacement video. it is $100 and worth every penny. www.ebfabman.com Before I bought mine I wished it were cheaper (most expensive single DVD I ever bought)...But...after watching the 3 DVDs that some...I am telling you it will have saved me untold dollars (more than the price of the DVD), cuts scrapes, bruises and generally swearing like a sailor. Also... http://www.67-72chevytrucks.com/vboa...ghlight=rocker Tim __________________ 1992 1500 4x4 Shortbed 1984 Ford F250 Supercab Longbed 6.9L Diesel 1972 K10 Cheyenne Super Fleetside Short Bed - 350 - A/C 1971 VW SuperBeetle 1960 Wife 1984 Son 1986 Son 1989 Son Previous Trucks 1967 C10 SWB (1980-1981) 1971 C10 LWB (1998-2004) Last edited by timcos; 01-26-2007 at 01:03 PM.

01-26-2007, 01:47 PM	#8
krue Designated A-hole! Join Date: Mar 2003 Location: South Mississippi Posts: 36,448	Re: Any Tips on replacing rusted outer Rocker Panels?? For rockers it shows what you need to do (plus it shows techniques to use for any patch panel). It's not as polished as some videos but it is informative. __________________ "If it ain't broke, fix it 'til it is!" Being stupid ain't illegal. We're Still Debt Free Except for the House!!! www.daveramsey.com 70 GMC SWB Stepside project "Green Booger" soon to be 6.0l/4l80e 93 S-10 "Poppaw's Truck"

01-26-2007, 01:56 PM	#9
kxnomore Registered User Join Date: Dec 2006 Location: CA Posts: 331	Re: Any Tips on replacing rusted outer Rocker Panels?? The classic trucks site was good too. How did you guys locate the spot welds when drilling them out? I looked around but they seem very tough to locate.

01-26-2007, 02:39 PM	#10
rophle1 Registered User Join Date: Jan 2007 Location: Athens, GA Posts: 112	Re: Any Tips on replacing rusted outer Rocker Panels?? Can bodywork beginners like me get anything useful out of these videos, or do you already need to be skilled at fabrication?

01-26-2007, 10:15 PM	#13
ks147j111928 ASE Certified Spoon Operator Join Date: Oct 2006 Location: Colorado Springs, CO Posts: 157	Re: Any Tips on replacing rusted outer Rocker Panels?? KX-I re-spot welded on the ends and skip welded across the floor panel. Don't you hate when metal warps towards the end of a long panel? I used some Corroless primer from Eastwood then 3M undercoated the insides for rust prevention. Hope it works... at least until I sell it someday?? __________________ My six is bigger than your eight 67 K20 292 +.060" SM465 NP203 3.73s 86 4Runner, the daily on 31s 85 4Runner, the wheeler on 38s 92 x-cab truggy project for 2017... tons and 42s and V8 power

01-26-2007, 10:20 PM	#14
kxnomore Registered User Join Date: Dec 2006 Location: CA Posts: 331	Re: Any Tips on replacing rusted outer Rocker Panels?? Thanks KS. My only issue now is finding the spot welds to drill them out. If I can't find them then the framer's best friend (sawzall) is going to make an appearance! I'm going for it tomorrow and will post pics of the progress...

01-26-2007, 10:42 PM	#15
rage'nrat638 Account Suspended Join Date: Mar 2003 Location: THE FALL GUY CHICAGO IL Posts: 5,883	Re: Any Tips on replacing rusted outer Rocker Panels?? heres a few of my rust job.. my 19 year old son @ the time, did mine Last edited by rage'nrat638; 07-12-2007 at 06:58 AM.

01-28-2007, 01:21 AM	#16
kxnomore Registered User Join Date: Dec 2006 Location: CA Posts: 331	Re: Any Tips on replacing rusted outer Rocker Panels?? All right, here's an update. It took lots of drilling, peeling, and chiseling, but the rocker panels are free at last!!! By the amount of spot welds you would think they built these trucks to last or something! Just my luck though that the rust didn't stop at the rocker panel. It extends into the floor and even up the kick panels. I have some thoughts about grinding out the rust that's left and fiberglass repair over the holes??? After placing the new rocker panels, of course. Anyone delved into this type of never ending rust?? The rest of the cab seems ok. The supports and all the middle part of the floor is great. Any ideas? Attached Images

01-28-2007, 02:39 AM	#17
Aarons72s Registered User Join Date: Apr 2006 Location: oklahoma Posts: 10,669	Re: Any Tips on replacing rusted outer Rocker Panels?? Yes i have seen alot worse! I ended up replacing almost 75% of my floor and have did a outter floor replacement on a 67 to. Unless you get rid of all the rust and treat the metal and you fiberglass over it it will just come back to hunt you. Can you get me a pick of your kick panel so I can help you more? how is your front lower cab corner, the one with the tab that holds the fender on? Can I get a pic of that to? Looks like you will need a front floor pan, kick panel and front cab corner from what you are saying. You may also want to check the front cab support to. My green and white is starting to look like that and is going to need the cab support to. Last edited by Aarons72s; 01-28-2007 at 02:40 AM.



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01-28-2007, 07:32 PM	#18
prostreet1967 Registered User Join Date: Oct 2006 Location: fort worth texas Posts: 395	Re: Any Tips on replacing rusted outer Rocker Panels?? the dummy that did mine put the rockers on top of the old ones then my door wouldnt shut so i dont think i can get to the spot welds

01-28-2007, 09:42 PM	#19
shifty Questionable Join Date: Mar 2005 Location: Atlanta Posts: 13,373	Re: Any Tips on replacing rusted outer Rocker Panels?? I'd suggest buying EbFabMan's video: http://www.ebfabman.com/ It will give you a reference video telling you all the tricks and tips to do it. I mean, you're already neck deep, but .... __________________ If I've got anything up for grabs, it'll be here: 7-hole gauge cluster for a 67-72 p/u FREE (link) I can't check the forum daily. If I don't reply to you within 24 hours, drop me a PM! I'm (hopefully) still alive and will reply faster to a PM. Last edited by shifty; 01-28-2007 at 09:43 PM.

04-14-2016, 08:00 AM	#21
Lanman1972 Registered User Join Date: Dec 2013 Location: Omaha NE Posts: 620	Re: Any Tips on replacing rusted outer Rocker Panels?? I read through a bunch of build threads, you tube and did a search for Rocker Panel on this site. Gain as much knowledge as you can. Make sure to fit/align the Doors and Gaps before final welding.

04-14-2016, 02:28 PM	#22
Orange Crate Registered User Join Date: Feb 2011 Location: Under the Truck Dreaming Posts: 755	Re: Any Tips on replacing rusted outer Rocker Panels?? X2 ^^^^^^^^ Make sure you hang your doors and check for fit and gaps BEFORE you weld. You will be good at all this when you move over to do the other side! __________________ 72 K20 Custom Camper, D60, 14BFF, full roller 406 TPI w custom built ECU and yes..it has tow hooks...and a 5 speed

04-14-2016, 06:42 PM	#23
5567Cruiser Registered User Join Date: Jun 2011 Location: Cannon Falls,Minnesota Posts: 99	Re: Any Tips on replacing rusted outer Rocker Panels?? I found some NOS GM rocker panels from a friend that bought them about 20 years ago and when you use OEM panels they fit perfectly with no problems with doors and line up. The factory assembly manual is a great help for locating the spot welds on the old panels and I remember 37 of them and I used a spot weld drill by Eastwood that worked very well. __________________ GARY 67 LWB CST FLEET 56 CHEV 3100 55 CHEV BEL AIR 2DR SEDAN 67 BUICK GS400 CONVERT

06-30-2016, 03:08 PM	#24
sick_46 Registered User Join Date: Jun 2016 Location: Adel Ga Posts: 16	Re: Any Tips on replacing rusted outer Rocker Panels?? My drivers side rocker panel is rusted all the way up into the floor. If I buy the drivers floor pan do I need the inner rocker panel also or is that part of the pan?

06-30-2016, 03:12 PM	#25
geunther Senior Member Join Date: Apr 2005 Location: Cheyenne, WY Posts: 740	Re: Any Tips on replacing rusted outer Rocker Panels?? Inner is part of the floor.

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