Rocker Panels

[Marmite]

Hello,

I recently bought a 2007 XLT. It's in pretty good shape apart from the rocker panels. Underneath they are rusted out but fortunately the rust isn't visible from the side.
So I am planning on cutting out the rust, and then adding a slip on rocker panel that I can screw onto the truck.
What concerns me, given my lack of experience with body work, is getting a pair of rocker panels that fit well. Can anyone recommend a good product/brand to buy?
I've wasted hours on youtube without finding really good advice on how to get the job done so any tips or links to good websites, channels would be appreciated.

Many Thanks!

 

[TobyU]

Just don't pay for the ones made out of siding gutter flashing material.
You can do that yourself cheaper.
Depends how great you want it to look. Since you will not see if unless you get under it, you could take any metal or aluminum maybe better and put a bend in it to fit.
You only need to get it flush on bottom or slight overlap that you can screw, rivet, or bond at and then ren it back to another bend or floor pan and hook it there too.

You don't need an exact fit overlay or replacement.
You can also cut the rough edges off hammer them over flat and then paint with rustoleum and then undercoat the heck out of them to make it look better than rusted jagged rockers.

 

[x1050er]

I got my rockers from Browns of two rivers. Complete rocker panels, cut off and weld on replacements.

Part numbers: 579A-04L and 579A-04R

These are listed for a 2006 XLT but fit my 2008 XLT perfectly.

They do offer slip ons as well

 

[mjp2]

I got my rockers from Browns of two rivers. Complete rocker panels, cut off and weld on replacements.

Part numbers: 579A-04L and 579A-04R

These are listed for a 2006 XLT but fit my 2008 XLT perfectly.

They do offer slip ons as well

^What this guy said. The up-to-06 rockers fit the 07+ trucks but, at least the last time I checked, nobody offers anything for the EL. Properly replacing full rockers on the EL involves buying 4 '06 rockers and cutting/splicing to get the extra length.

 

[Marmite]

Thank you for the replies.
One more question.
The holes in the section of the body underneath that the rocker panels attach to. There are 4 round holes and then a longer circular shape.
I think that these are the cause of the rust so they need filling.
Any recommendations about what to use?
I imagine I can get some plugs at HomeDepot and online but if anyone knows some good ones I would appreciate it.

Thank you!

 

[JExpedition07]

Are you talking about behind the rockers? Those would be factory holes there if it’s the inner rocker panel. 3-4 big holes per side then a series of small ones.

 

[Plati]

Thank you for the replies.
One more question.
The holes in the section of the body underneath that the rocker panels attach to. There are 4 round holes and then a longer circular shape.
I think that these are the cause of the rust so they need filling.
Any recommendations about what to use?
I imagine I can get some plugs at HomeDepot and online but if anyone knows some good ones I would appreciate it.

Thank you!

I agree! My buddy Polarizer taught me how to do this.

I tried to buy them and tried a variety of rubber stoppers, PVC plugs and caps, black iron plugs, etc. Never found anything that fit and they also weren't cheap (I am). I'm sure there's something out there somewhere and would be interested myself. I think there are 3 different sizes, making it a little more difficult.

So I made my own out of stuff laying around (free). Also, doing it this way I could make the exact size I wanted since there are a variety of different sized and shaped openings. I did go to Dollar Store and buy little toy balls that work pretty well (a buck apiece). For others I used foam (pipe insulation) that I cut to length and rolled up, giving me the diameter and length I wanted then skinned with Gorilla Tape. Easy to make. Work perfectly, durable. You can compress the plug, fit it in 1/2 way, and it expands and gets stuck solidly in place. I think I could start a business making these things if I was entrepreneurial, but very few people have any interest in saving their rockers anyway.

The oblong shapes where running boards attach, I just jammed the foam in there as best I could. That area was tough. I Fluid Filmed the inside first.





I really feel like if you cleaned the area really well first, you could just apply Gorilla Tape over the hole. I generally over engineer my stuff so I wanted the bulletproof plug. A lot of Ford Trucks come with tape over those holes (that falls off after a few years) - so you know that Ford knows those holes should be covered or plugged.

https://www.f150forum.com/f38/duct-tape-rocker-panels-really-99420/

 

[no MORE_MPG]

Hello,
Having read the F-150 forum post, I had the same questions that were discussed here. The bottom line here seems to be that these holes should be covered.
Maybe I should have posted here, though I tried to reply to the thread, "Question about factory rocker panel holes" first.

Any help/suggestions would be appreciated!

If I am breaking any posting etiquette, please feel free to guide me to a better way.

 

[Plati]

Hello,
Having read the F-150 forum post, I had the same questions that were discussed here. The bottom line here seems to be that these holes should be covered.
Maybe I should have posted here, though I tried to reply to the thread, "Question about factory rocker panel holes" first.

Any help/suggestions would be appreciated!

If I am breaking any posting etiquette, please feel free to guide me to a better way.

Not sure what your question is .... ?

Easiest, cheapest, quickest way to plug the holes is with one of those pool noodles.
Can cut & trim to any size quickly.
https://www.lowes.com/pd/Inno-Wave-...Vj8DICh1gZQG3EAQYAyABEgIQxPD_BwE&gclsrc=aw.ds

they don't cost much
even better ... steal one from a kid in a pool

 

[no MORE_MPG]

Hi MrSticker,
Thanks for the reply!
Sorry I wasn't clear.
Should these holes be covered? - This thread seems to say, "Yes".
Is it OK to cover them with aluminum flashing and liquid nails?

Additionally, I would love some feedback on my other post (Question about factory rocker panel holes). Am I on the right track in addressing this problem on my Expedition?

 

[Plati]

Hi MrSticker,
Thanks for the reply!
Sorry I wasn't clear.
Should these holes be covered? - This thread seems to say, "Yes".
Is it OK to cover them with aluminum flashing and liquid nails?

Additionally, I would love some feedback on my other post (Question about factory rocker panel holes). Am I on the right track in addressing this problem on my Expedition?

well ... i think they should be covered but i only cover (plug) them for winter
i like to flush them out in the spring to get the crud out ... and use the holes for that
but ... why are they there to begin with? i dunno
even after plugging mine, crud gets in where the running board is mounted
https://www.expeditionforum.com/threads/wny-rust.34632/page-3#post-302178

 

[no MORE_MPG]

My Passenger outer rocker looks a bit better now.

Patched with galvanized steel that I could bend without a brake (26 ga.). These have been glued and riveted in place.

Since these pictures, I have bondo'd over this and painted it black for now.

Also, I stripped most of the surface rust from the frame and coated it with POR-15 and satin black Rust-oleum.


I have not covered the holes in the inner rocker panels. The entire inside (that I could reach when the big hole was open) has been coated with POR-15. Maybe that's good enough. Now I can wait for the driver's side to do the same thing, or maybe park it on a hill and then on a dry day, just pour some POR-15 in the up-hill hole.

 

[Frosty]

I got my rockers from Browns of two rivers. Complete rocker panels, cut off and weld on replacements.

Part numbers: 579A-04L and 579A-04R

These are listed for a 2006 XLT but fit my 2008 XLT perfectly.

They do offer slip ons as well

I have a 2009 Eddie Bower. It is in very good shape except for the rocker panels. In the jurisdiction where I live it is required that it pass an inspection. In order to register the vehicle I am required to repair the rust according to OEM specifications. The question I have; Did your installation of the panel on your 2008 require modifications to the OEM panel purchased from Browns?

 

[ManUpOrShutUp]

I have a 2009 Eddie Bower. It is in very good shape except for the rocker panels. In the jurisdiction where I live it is required that it pass an inspection. In order to register the vehicle I am required to repair the rust according to OEM specifications. The question I have; Did your installation of the panel on your 2008 require modifications to the OEM panel purchased from Browns?

Your truck won't pass inspection with rusted rockers? We have safety inspections here as well and it's a non-issue.

 

[Frosty]

No it won't pass unfortunately. They claim it is a safety issue with a side on collision. The only way I can get it to pass inspection is to replace the rocker panels on both sides with OEM parts using OEM specifications. Ford will sell me the parts for $7000.00 (which includes the door frame and quarter panel) and then I am required to use their OEM specs for replacement. If the OEM panels from Browns need to be modified in any way it won't pass either.

 

[JExpedition07]

No it won't pass unfortunately. They claim it is a safety issue with a side on collision. The only way I can get it to pass inspection is to replace the rocker panels on both sides with OEM parts using OEM specifications. Ford will sell me the parts for $7000.00 (which includes the door frame and quarter panel) and then I am required to use their OEM specs for replacement. If the OEM panels from Browns need to be modified in any way it won't pass either.

Order the keystone panels for the 2006. It’s the same panel. It will pass. Nobody can tell. Have a body shop do the work and take it somewhere else for inspection.

I bought a set of the OEM’s, mine were replaced...the outer rockers are tin foil and offer no help in a crash. These are cosmetic and for a toe-kick. The inner rockers are triple thickness and are your safety. Those also don’t rust out on these.

 

[Frosty]

I can get the keystone panels locally and don't have to pay shipping but they look like the slip on ones when I look online. The other issue with them is that I am required to produce the invoice for my purchase and it needs to specify OEM. I phoned keystone and they say theirs are not specified as OEM. Oh and I am also required to replace the inner rockers as well but that's not the problem since I can get those from our local Ford dealer for $150 each.

 

[TobyU]

I'd just move. Apparently it's a scam to get older vehicles off the road. This is not a safety issue. It's complete bullcrap.

I would certainly win though! Regardless of what I had to download off the internet, cut and paste so I would have a receipt to show them that said OEM. That description text can be found anywhere.
All pencil pushing geek rules are meant to be circumvented.

 

[JExpedition07]

I’m not really buying it. So any 00-2010 vehicle that rusts that you literally CANNOT get oem panels from for must be removed from the road? Not so sure your state inspector knows what he’s talking about. I’d get a second opinion from someone else.

 

[ManUpOrShutUp]

Well, it seems rockers are considered essential to "body integrity." ******** imho.

https://www.th.gov.bc.ca/cvse/vehicle_inspections/PDF/Structural_Integrity_Process_Guideline.pdf