Cut & weld outer rocker?

elflamo · 12-02-2007, 07:35 PM

Hi all,

I had the outer rocker, rear quarter panel and door locking plate replaced by a shop. Turns out that they should have replaced the inner rocker panel as well. So what I did is remove the outer and inner rocker all the way from the front up until the jacking point (which is in fairly good condition, replaced the tube). Now, as I don't want to disturb the fresh new original Porsche panels of the rear quarter and locking plate, would it be acceptable to weld the inner rocker plate to the jacking point and weld the outer rocker panel to the remaining part of the 'old' new outer rocker panel, just at the point where the rear panels come together (where the factory lead is).

Would this be structurally sound? I reckon I should not butt weld but overlap and weld?

Thanks

Dennis
911S 1972

elflamo · 12-03-2007, 07:30 PM

C'mon, surely some of the body resto experts have an opinion?

Thanks

Dennis

elflamo · 12-04-2007, 01:00 PM

Can I just ask for Milt or Darryll to chime in pls? I would like to get moving on this project soon.

Sorry for bumping again

Dennis

plain fan · 12-04-2007, 03:19 PM

Dennis,
Do you have pictures of the area with the outer rocker panel removed? I wish I could help you with your question, but I may be looking at performing the same operation as you and was curious to know if you had pictures.
TIA,
Grady

Zeke · 12-04-2007, 03:49 PM

Quote:

Originally Posted by elflamo

Hi all,

I had the outer rocker, rear quarter panel and door locking plate replaced by a shop. Turns out that they should have replaced the inner rocker panel as well. So what I did is remove the outer and inner rocker all the way from the front up until the jacking point (which is in fairly good condition, replaced the tube). Now, as I don't want to disturb the fresh new original Porsche panels of the rear quarter and locking plate, would it be acceptable to weld the inner rocker plate to the jacking point and weld the outer rocker panel to the remaining part of the 'old' new outer rocker panel, just at the point where the rear panels come together (where the factory lead is).

Would this be structurally sound? I reckon I should not butt weld but overlap and weld?

Thanks

Dennis
911S 1972

Just saw this. Absolutely yes, you can do a partial repair to any point you want to. Sorry that your shop didn't do it right in the first place.

Again, I have left the jack reinforcement plate intact and welded up to that point and no further. Turned out well.

elflamo · 12-16-2007, 11:40 AM

Hi Milt, just to confrim, the attached picture show the cuts I made and the outer rocker area I'm planning to weld to. Based on your reply, I assume this will work allright?

Another pic shows the nice condition of the rocker inside (after media blasting that is).

Thanks

Dennis

Fleming · 12-16-2007, 09:32 PM

Here is a photo from over on the 911S Registry site:

http://www.early911sregistry.org/forum/showthread.php?t=18320

This shows the inner panel has a joint to the rear inner fender just to the front of the jack point support (support not installed yet). It looks like a butt joint or a flanged lap joint, cause the material does not have a two layer look at the sill flange or at the bottom where it joins to the floor pan.
Bob

elflamo · 12-17-2007, 12:20 AM

Helpful picture, thanks. However, I was actually looking for confirmation on the welding of the outer sill.

Thanks

Dennis

pozee · 12-17-2007, 12:41 AM

The inner piece (longitudinal) is the main structural support. As Milt stated, what you are planning is fine. The inner piece is critical - the outer, not as much.

Just make sure the door bottom lines up to your liking and weld in the outer rocker. Butt or overlap, not an issue.

Fleming · 12-17-2007, 04:24 PM

Like Pozee said. Butt or a tight lap would work.

This rocker panel was opened for the oil lines. Interior was POR-15'ed prior to closing. Verify gaps and panel contours prior to welds.

The outer panel was top edge butt weld and the rear top and back has a 1/8 overlap - most of which was incorporated into the weld bead when it was done. The bottom was rosette plug weld and ground to look similar to the original spot welds. Minimum filler was needed at the welds to get back to the final shape.

Bob