Anyone dealt with rotting rocker panels?

[Paul Prekeris]

Not a welding expert, but welding galvanized metal can be an issue. Zinc fumes are toxic and you need to grind the coating to get a decent weld.
Though i like the idea of using galvanized sheet metal for rockers, but im not sure of unintended consequences.

 

[sjwelds]

may as well go stainless. never rust then.

 

[Paul Prekeris]

would love to go stainless.. In a couple of years, the rest of the truck will rot away but the rockers will look great...

 

[cjbuckeye]

do the 06 rockers fit the 07's? I cannot find 2007 rockers anywhere! driving me nuts, bought an 07 with visible rust issues with bubbles on the fenders and rockers. I negotiated down based on the body work being needed but didn't think it would be so hard to do! My local ford dealer quoted me $3,000 since there are no factory panels available and it's all customer fab.... Anyone have luck with repairing the 07 Expeditions?

 

[mjp2]

My fabricator is interested in taking on the job but hasn't had time to dig into it just yet. He's got a number of bigger projects ahead of me but I'll see if I can get some movement on this.

 

[JExpedition07]

Apparently aftermarket companies aren’t going to step up to the plate and have no interest in selling panels for these trucks. Still haven’t tackled mine, I’m sure the 06’ OEMs I have are NOT a direct fit there will be alterations made. The slip on rockers are listed as 03’-17’ however. The BS excuse by ford that “it’s a part of the door frame” is a big smelly pile of crap. The 06’ and 07’ panels are 98% alike as far as I can tell. I rattle canned mine a red temporarily so they don’t rust in the garage.

 

[mjp2]

Those look damn close to the right fit. Where are the differences you're seeing?

 

[JExpedition07]

Those look damn close to the right fit. Where are the differences you're seeing?

I don’t see many. The angles and door openings all appear to be correct. The only thing I’m not certain on is if these tabs that go up onto the inner rocker will be matching up....but I’d think anyone can be creative and make it work by fabricating something up.

 

[HawkX66]

I just posted a response to another thread about this. My 07 rockers turned to dust in Michigan. I took the last inch or so that was solid and cut it out for the profile. I took that to a metal shop and had them bend up two rockers. $75. Couldn't beat it. The slip ons are a waste IMO. Not much more than gutter material. At a metal shop you can get the right gauge/thickness.

20170723_124110 by Dave H, on Flickr

20170723_124302 by Dave H, on Flickr

20171203_145923 by Dave H, on Flickr

20171203_150027 by Dave H, on Flickr

20171203_160102 by Dave H, on Flickr

20171204_143709 by Dave H, on Flickr

20171204_143714 by Dave H, on Flickr

20171204_143721 by Dave H, on Flickr

Other than the rockers, the rest of my 07 looked great.

20170723_125104 by Dave H, on Flickr

 

[HawkX66]

This is probably a dumb question by why wouldnt you make rocker panels out of galvanized sheet metal like duct work is made out of? It would have much better corrosion resistance.

Because you shouldn't weld galvi. Fumes are pretty poisonous. Also, once you cut galvi, you remove the galvanization. It's a coating more or less.