Is there a definitive guide to rocker panel replacement?

[rennch]

As much as I like tinkering with it...I'd much rather drive it!

[artisticent]

Hey,

This is exactly where I am too. The rockers are a a chore. I have also decided to weld on new rear quarters as mine will need filler and im not in to that.
Good luck
Nathan

[rennch]

So, I ordered new jack support plates and inner rockers. I'll update you when I get the parts.

[artisticent]

Where did you get those, and why the inners??
Nathan

[rennch]

Restoration Design. And I needed 'em....

I have a couple of spots on the inner that I need to replace, unfortunately.

[artisticent]

I know it never ends. Im now shaving the rain gutters and welding the roofline. I really never realized how much it strengthens the car by eliminating the 3 piece crimped metal and doing it right, not to mention it looks really cool.
Nathan

[rennch]

I don't know a thing about that. What roofline?

[artisticent]

Look at the rain gutter threads, its very interesting although it will start you down an expensive tedious road.
Nathan

[rennch]

Well, I'm making some progress here, but I'm having a hard time "grinding down" the metal to get rid of the spot welds. anyone want to share their technique?

[rennch]

I *finally* got my inner rockers and jack support plates from Resto Design today. It only took 6 weeks. (He actually told me he was shipping it 6 weeks ago...)

After my flare install (Check my footer for the project 69'er) I feel better about doing these. It's only metal, right? What could possibly go wrong?

[rennch]

I got my inner rockers and jack supports today. I probably have at least another 30 min-1 hour of removal time. What a pain!

Some pics...

Jacked and leveled. I have a jack under the engine as well, and it's jacking the engine just enough to keep a lot of weight off the jackstands.




The inner rocker peeling away like a sardine can...


The Jack support and surrounding metal really needs to be ground down. I'm excited to get all the new metal in there.



The front of the inner rocker is still attached. I'm not totally sure where it disconnects, but I'm working on it...




The plan for tomorrow is to get everything cleaned up and the bad metal cut away. If I feel motivated, I might even break out the welder.

[village idiot]

You're making me antsy to get started on my car!!

Unfortunately I have a very large project currently taking up my spare time.

... A 1979 Pontiac LeMans station wagon that I'm doing for my friend/boss :/

[rennch]

Ok, I'm back after a 2+ week layoff. I was with my sick mom in FL, then to Crested Butte CO for a mountain bike vacay over the July 4th weekend. I hated to leave it, but alas...

Here's where I am. The inner rocker has been removed. Everything is cleaned up, has been POR-15 metal-prepped, and POR has been applied at some areas that might be troublesome in the future. I've test fitted the pieces, ground away excess material, and am ready to weld as soon as the POR dries completely. Pics:

Inner rocker piece drilled for spots:



Close up:



Jack Support Pre-drilled:



POR-15 Metal Ready Applied. The foaming indicates it finds some rust to convert to Zinc. Cool!



nuther':

[rennch]

A few more:

POR-15'ed:





Where I stand. Next up, clamping, and welding.



See you on the other side.

[rennch]

Ok, the inner is in, as is the jack support. Woo Hoo!

I'm glad I don't have to grind a ton off either...that's a good thing.

I was having a problem with the seam towards the rear of the car, but I found when I sped up the feed a bunch, the welds got a lot better. Go figure.




I would love to get the outer on tomorrow, but I'm just about out of juice. (Welding Gas, that is.) So, I'll finish up any welding on this, grind a bit, and get the outer fit. Do you think I should POR-15 the jack support?

Until then....

[village idiot]

Looking good! I'll be starting on mine shortly, as I've gotten my bosses car in primer.(finally)

[rennch]

My recommendation on this is only replace the metal you need to. Don't take it all apart if you don't have to. I'm going to follow that advice for the driver's side. Just patch if I can get away with it.

[jamesnmlaw]

Where can I get a couple of the heater tubes that run inside the rocker?

Really want to drive in the winter this year, and have warm feet.....

[rennch]

Inner rockers buttoned up. I hit them with some weld thru primer before I plug welded the outers.


Inner, all primered and ready to go.



Prelim fit on the outer. I got pretty lucky, actually. I only had to put the door on once, make some small adjustments, and tack it in. My gaps look really good. (More on those later.)

[rennch]

Here's the outer, all fit, adjusted, and primered. This was definitely the most daunting task I've had on the car. I made LOTS of progress today, and had some great, great news. (More on that later too..)





Check out that pretty gap. I got really lucky.


And here's the gap in the front seam, aligning the door and fender with the rocker. lucky again.



It's hard to believe it was so rusted out...the before pics of this are pretty remarkable to me.