Anyone dealt with rotting rocker panels?

[Plati]

MrHawk ... That metalwork got my attention, I'm impressed. I may try to figure out how to do that when I get home. If I don't do something I think I'll have water in the cabin by spring. Floorboards also gone.

 

[HawkX66]

MrHawk ... That metalwork got my attention, I'm impressed. I may try to figure out how to do that when I get home. If I don't do something I think I'll have water in the cabin by spring. Floorboards also gone.

Thank you. All in all it wasn't a bad job. It wasn't my 69 Camaro, so I didn't even bother butt welding the seam along the top. I cut it so it matched up with a curve that makes it easy to blend. Sad part is, I haven't done that yet. I moved from Michigan to Virginia in June, so maintenance like that has taken a back seat. It looks decent, is solid and protected now so I'm good with it until I'm ready to finish. At 210k on the clock, let's hope that's the only thing I have to worry about. She still runs and drives beautifully. The only mechanical issue is a rear end whine from some hard core towing through Kentucky and Tennessee mountains/Appalachia. I changed the rear end oil and it hasn't gotten any worse so I can deal with it.

 

[bobmbx]

Has anyone looked into the function the rockers provide? Just wondering if they are involved structurally in side impact testing/ratings, "crumple zone" design, or if they provide any other structural (strength member) function.

If they don't, then why not use plastic or aluminum as a replacement material?

 

[HawkX66]

The Expedition is a full frame vehicle, so no, the rockers aren't necessary for structural integrity. Do they help? I'm sure they do. As far as the material to fix them? Plastic? I hope that was a joke... If it's worth fixing, it's worth fixing right within reason. Everyone has different opinions on what fixing things really means. Some people are alright with spray foam or fiberglass to hide damage. I don't subscribe to those "repairs."

 

[JExpedition07]

I went and bought the supplies today for this and sharpied my lines where I’m cutting the old out. That’s enough work on the expy for one day lol. If I get time later I’ll be taking the running boards off permanently. They won’t be going back on as they are just snow/ salt traps.

 

[JExpedition07]

The Expedition is a full frame vehicle, so no, the rockers aren't necessary for structural integrity. Do they help? I'm sure they do. As far as the material to fix them? Plastic? I hope that was a joke... If it's worth fixing, it's worth fixing right within reason. Everyone has different opinions on what fixing things really means. Some people are alright with spray foam or fiberglass to hide damage. I don't subscribe to those "repairs."

Hawk did you remove your doors when you did this? My rockers are solid except for the bottom portion and I’m considering slicing off the door openings off the new ones if I can avoid removing doors. I could also cut right to that middle “line” where yours end and that would replace more than enough material. Like I said everything up top is good minus one spot.

 

[HawkX66]

Hawk did you remove your doors when you did this? My rockers are solid except for the bottom portion and I’m considering slicing off the door openings off the new ones if I can avoid removing doors. I could also cut right to that middle “line” where yours end and that would replace more than enough material. Like I said everything up top is good minus one spot.

No, I didn't remove my doors. It gets a little tight at the front of the rear door, but is very doable. I only cut what I had to, then sealed the bare metal edge. If you're butt splicing it's a little more tricky, but lap welding is easy on this one.