Rust repair rocker guards area

[MarkEMS3]

Im sure this has been covered somewhere, and being a NOOB to this forum someone should have the answer.

my 05 limited has some rust, under the rockers on the panels that use to run from frame to body to prevent exhaust fumes and such from entering cab. Not the panels on the doors but underside of the body. It was a Upstate NY Expy and unfortunnatly saw a lot of salt and not well maintained. It passed inspection but I have looked at it, I am the 2nd owner and when I bought it last year the dealership bondo'd the area and spray bombed it and I never caught on till it fell off (both sides of veh) about 2 months ago. I was told there are replacement covers/slip panels that I can get and tack weld them in there, but have been 100% unable to locate such on the internet.

Also, anyone experienced a almost rusted through Radiator support, Im thinking about just running a piece of angle iron across there and welding it in and being good to go.

Thanks in advance.... I can get picture if what i'm explaining bout the rocker doesnt make sense.

 

[Norexp]

I am living in Norway, and there is lots of salt on roads here also. Therefore my rocker panels are very soft.

I took an angel grinder, and cut out the worst. The remainings I have treated with acid, and brushed on plenty of fluid film. Because of that my rockers are open, and as a middle thing I thought about covering up with some patch panels. Best would of course be new rocker panels, but as you I havent found them either.

Im quite sure someone else here have rust on the rocker panels, and can share some experience.

Good luck sir!

 

[stilbo]

My 2003 Expy has rot on the BOTTOM of the rockers...

Found these on ebay but not sure if they wrap around the bottom...

Rocker Panel 4 Door Ford Expedition Navigator 2003 2006 Pair Left Right | eBay

 

[walnuts4x4]

might wanna check out LMC truck and get one of their free expedition catologes and see if they have what you need.... I'm at work and can't pull up their website

 

[Moemantha]

Yeah those panels will wrap around the bottom. Its best to trim most of the upper portion and just use the side(vertical) and bottom. It will fit a lot better.
You will need a mig welder w gas. Best to screw-clamp them in and check gaps clearances- door bottom etc.. Then weld. Use plug welds along the bottom under the truck, and tack the sides every inch or so. You could solid weld it as well. Just fill in the gaps between the tacks till its welded solid.

 

[stilbo]

Thanks Moemantha.
So if I trim the top off I'm actually trimming the area where the panel becomes the bottom of the door jamb?
How much overlap do you suggest (at the top?)? Or butt weld it all?
The last big panel weld job I performed was the floor of my '70 Ranchero GT and even though the oem style panels went in nicely... I'm glad it's all covered with Dynamat and carpet!

 

[stilbo]

One more thing...
Since this area is so prone to rust, does anyone have any suggestions as to how to coat, treat, paint or otherwise protect the INSIDE of the rocker cavity?
Moving to New Mexico would be nice but I have four years until retirement.
Thanks

 

[Big White]

One more thing...
Since this area is so prone to rust, does anyone have any suggestions as to how to coat, treat, paint or otherwise protect the INSIDE of the rocker cavity?
Moving to New Mexico would be nice but I have four years until retirement.
Thanks

Spray the hell out of it each season with anti corrosion oil. My plan anyway.

Rust Cop - Rust Control Product for Home Use - Cars, Bikes, Equipment

 

[Moemantha]

I'd leave 1/4-3/8 overlap. Do not buttweld. Pain in the ass. This is no restoration.
Yes trim the top floor board section off . I never use that part unless its rotten too. Autobidy supply stores sell cavity wax/oil for rustproffing.
Get the panel all screwed in and fitting. Scribe your overlap onto the trucks rocker. Remove the rocker and trim the overlap 1/4" or so below the scribe. Use tape to mark it if you wish. Just be sure to cut on the right side of the scribe leaving it long for overlap.