Need help with 66 rocker panel repro giving me trouble

[msg]

Anyone ever have this problem with the height of the rocker?
Looks like the repro panel is taller in its profile than the original by 10mm or more.



Looks like I need to make a cut to the left side and remove about 10mm of the brace. Then I can bend it to reduce the height. Sound right?



I assume that GM decided that putting a plug hole in the rocker panel was to have access to clean it out, but who would really ever need to take a fender off to pull the plug and access the innards of the rocker? Would welding up the hole be a mistake?

[patrickk1]

Hard to tell from the pics but it looks like the profile of the rocker is off a little. I would first trace the profile of the old rocker end onto some cardboard. Trim so it's perfect and then hold it against the new rocker end. From there, it looks like you should be able to make a pie cut on the end part and fold in slightly. The upper portion of the rocker end might also need to have the spot weld drilled out and bent slightly to match the original. The rocker template will help you figure out what needs to be done to get it perfect.

Makes me wish I hadn't thrown away my old rocker since I haven't welded my new one on yet, although my recollection is that mine looked good when I last looked at it last year.

[msg]

Thanks Patrick, I had planned to cut that wedge out and shorten it up. Im not gonna worry about the plug hole and just weld over it. Just dont get why that plug is there since it drains from the channels underneath.

[patrickk1]

Originally Posted by msg

Thanks Patrick, I had planned to cut that wedge out and shorten it up. Im not gonna worry about the plug hole and just weld over it. Just dont get why that plug is there since it drains from the channels underneath.

I am completely guessing here, but maybe the hole was there so the inside could be painted/coated before the truck finished assembly at the factory.