Hey everyone ... I have a 1990 ext cab 4x4 ..... Havn't been diving it much as I am in the middle of putting on new exhaust . Today I was walking passed it to get into my car, and noticed the pass side fender looked off down near the door . So I grabbed it, and the thing was completely loose . I took the inner fender out to investigate .The front part of the rocker is completely rusted out and the pinch seem at the floor is starting to go . Funny thing is , no rust can be seen from the outside of the truck. I am looking for some insight on how to go about repairing this . Is it a lost cause ? Anyone who has done this before have some pointers ? All and any help is greatly appreciated .

 

Cut out the cancer and weld in a new piece. Then use some rust preventing paint like POR15 over it to prevent further rusting...
Is the fender itself rusted out?

 

I cut a good one out from another truck .. and welded it in .. it's pretty common area for rust .







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No the fender is perfect .... I think the PO must have put new fenders on and not delt with the underlying problems I think there is an issue with the drivers side floor as well ... I think i will just take the fenders and doors off ... strip the interior and do it all at once ...

 

Slacker, any chance you have done a complete rocker panel removal and replacement??? I have new rocker panels that were bent for me but have been waiting to cut out the old and weld in the new because I am a little nervous... Any pics or advice on what I have to do to do it right? Thanks

Shakes_24, when are you planning on doing this? Can you document it and share when you complete it? Thanks

 

I am planning on tackling this as soon as i get done installing the engine in my dads project car it's a 74 Pontiac LeMans sport couple... it's taking up to much room in my little shop for me to work on the truck . I will so a write up once i get started .....

 

yes , but never documented it ..
I have another unit already booked into my shop in May ( http://www.toyotafiberglass.com ) .. I know thats a long way away , but time flies !! so if you can wait .. I will be posting the complete build ..


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Unfortunately I can't wait until then... I have to have it done by January for my inspection. Any tips on what I NEED to remove or how I go about removing the old??? Thanks

 

post up a pic of the panels you have ..

 

This is the panel I order from Mill Supply... but it was not correct because it did not go all the way back to the cab corner (picture is the one I sent Mill Supply showing them the part was not an exact fit). However, the new one I have does so I need to cut out the old and weld in the new... Thoughts? Thanks

 

What thickned of metal should I be using for this repair? Thanks

 

20 gauge is what I was told for a solid rocker... I know some use 22 but that seems a little light to me.

 

Thanks quiggs I was thinking like 16 gauge or something but sounds like that would be overkill lol I will grab some 20 after this snow storm is over

 

Remeber to post some pics throughout your work... Thanks

 

Will do quiggs should be able to start soon

 

Another thought I have small 120v flux core mig welder. That should work alright for this job right... I don't see a problem with it. Anyone else think that will be a problem?

 

yep .. your welder should be fine for the job .

the outer rockers are not really structural , more a "finish" , most of the strength comes from the inner rockers .

quiggs.. based on the pics of that piece .. butt welding and spot welding would be best .. scribing the lines of the new piece first, onto the old piece .. and then remove the old rocker using a spot weld bit and a cut off wheel on your scribed lines .. Punch your spot weld holes on the new piece , and make sure everything fits ...

take your time with the welding .. space them out , and let things cool .. no warping aloud ..

and BE SURE .. after everthing is said and done , to "seal" your welds on the back side ..


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Slacker, I really don't want to screw this up... is there any literature you would advise me to obtain first? I am new to almost all of this... Thanks

 

I dont ... sorry


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it will just spatter a bit, pick up some flapper discs

120v flux core is what I have too