Passenger Rocker Panel Replacement

Both Rocker Panels on this tub are completely rotted out, so I started today on replacing them. The rot was concentrated in the rockers because the previous owner had installed Aluminum Diamond Plate here, likely to cover up some slight rust. Unfortunately, this method of "repair" acutally makes the rot get even worse. I had a sheet of 11ga left over from another project, so I decided to use this. Thicker steel in the rocker panels surely won't hurt. Today I got the Passenger side panel installed. First I removed the old rocker panel.

Next, with the opening size determined, I fabricated my replacement. To bend the 11ga, I cut a V groove almost all of the way through the steel on the back side. Then, using a hammer and a bench vice I bent the steel at the groove. Finally I laid a few 1" beads of weld to hold the bend from the backside and welded up the corners. Here's a back view of the finished product:

Next, I clamped and tacked the replacement into place for welding. It's a pretty good fit. The gap between the panel and the underside of the doorsill will weld up easily. Here's the panel tacked into place.

Finally, I welded the whole thing in, except for the front and rear edges, which are bolted in the original tub. I'll bolt these in like factory. I welded the panels in small segments so as to not warp the panels. These panels aren't too likely to warp much because of theturned under edge on the bottom and the thickness.

A little grinding and a skim coat of body filler should have these looking like new. Next up, Drivers side rocker!

Finally some progress

I finally got all 95% of the Frito Lay Van Scrapped and out of my driveway. This was really a pain in the ass, but it was worth it because between the scrap aluminum and steel and selling off the wheels, tires, and rear axle I broke even on the van and have the Cummins 4bt left for myself. I also was able to trade the Chevy Transmission and Chevy to Cummins Adaptor for a Dodge Adaptor and Flywheel to use a NV4500HD tranny!

Here's the last load of van heading for the scrap yard.
Next, I finally got some warm enough weather to paint the frame. Here's the frame fully painted andthe suspension and axles installed for the final time. After the paint dried, I installed the body for the first intial fittment. I'm not sure wether or not I'll have to remove the body one last time but I don't think so. I wanted to work on the body on the frame to avoid alignment issues if I had fixed it separately. It was actually pretty easy to put the body on myself using the engine crane as seen below...




It's really starting to look like a FJ40 now!


I'm going to replace the rear quarter panels because there's some good rot on those, and the "Comp Cut" makes the 35s look way too small. I'll also have to replace both rocker panels because the black diamond plate is covering some major Rot.

That's all for now!