how to remove outter and inner rocker panel

[Mukilteo911]

I need to replace the outer rockers of my 911 and have purchased the new ones. I have no idea what the correct way to get the old ones off the car are. Does anyone who has done this have the time to tell me how to do it ?

It seems like a common thing to do but in searching the posts from the past I did not find anything that described how to remove and replace the panels from start to finnish.

It looks like I can drill through the tacks at the threshhold, but beyond that I am lost.

Thanks all.

[TimT]

replacing the rockers isnt a cut and paste kinda thing. most body shops dont do it correctly.

To expose the inner rocker, you have to of course remove the outer rocker. to remove the outer rocker you have to unzip a number of welds at the bottom of the quarter panel, along the sill and at the bottom of the rocker

To properly do the job you have to give yourself some working room by cutting back the body/tub so you can clean the area, manipulate the welder etc...


check out my rebuild

[TimT]

oops the link only gets you to one page........ you can find the rebuild here

[Mukilteo911]

Thanks for jumping into the topic. Still looking for full details. Pictures of the cut areas would be great. I have seen people just cut it off in a square and then trim the new metal to fit in the hole they made. I would prefer to do it right and replace the whole thing. But by looking at the rocker panel on the car, it is not clear where the tack welds are along the seams or if it is continueously welded all around the bottom and side edges.

[jpnovak]

I am currently in the middle of this same project. Here are some pointers.

to understand how the car is put together you must first remove the fenders, rocker trim, door seals/thresholds, paint, lead filler and undercoating. At this point you will see a few things. There is a seam that makes up the seal channel. There will be hundreds of spots welds along this seam. They must all be drilled out. Next on the lower section of the outer rocker you will find another seam. Again more spotwelds to be drilled. The ends are a little different.

The front of the rocker fits nicely around the door hinge post. Try to mimick this unless the hinge post is rusted out(likely) The rear edge the rocker makes a sandwich. the layers (from outside to inside) are the rear quarter panel, outer rocker, inner fender support, inner fender. If you are careful with your cuts you can slide the new rocker between the quarter panel and the inner fender support. Getting in there to weld is a different story.

I ended up trimming the end of the new panel and tying it into the joint. I good weld will make it nice and sold here.

Once you have the outer rocker out you can follow the seams for the inner rocker. I did not have to do any work on my car here. The inner panel you may want to consider butt welding a patch piece depending on conditions.

When done coat everything with a liberal coating of POR15(or equivilent). Prime, paint. Your done.

Good luck,

Jamie

[Mukilteo911]

Thanks Jamie,

To get the lead out, I supose my brazing torch will do, any tips on this ?