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!