Autobody workers worry about rust on rocker panels
15 posts in the last 60 days, all from r/Autobody.
“Ah, okay, that makes sense, I thought I was looking at a front fender and couldnt figure it out. Rear quarter rust is a bit worse, as it is part of the unibody and continues directly into your rocker panels. And on a van with a sliding door, this might be an even bigger issue…”
“I recently ran into a F-250 the engine and transmission is top notch and in good condition, the issue I’m running into is the rust. I realize I need new rocker panels (inner and outer) but my concern is where the underbody meets in the inner rocker panels, they seem completely…”
“Went over a curb about a week ago and wanted to know what the best course of action would be to repair such a thing. I was thinking of sanding this out and putting some rust inhibitor over the scratch and the just putting a adhesive rocker panel cover over it to cover it. I'm on…”
Several posts discuss the challenges of modifying and repairing rocker panels, with a particular focus on dealing with extensive rust. Users share techniques for bending flanges and plug welding, while also expressing concern over the extent of corrosion.
SOURCES (25)
“as a bodyman the only way youd get me to do it is replace all metal rusted with new pieces. Id want new inner and outer rocker panels, and cab corners. hopefully you wouldnt need any more then that. I wouldnt touch it any other…”
“The damage to the rocker panel is minimal. I wouldn't use major repair methods for this. [re: How would you go about repairing this on a 2013 Honda Accord?]”
“Replying specifically to replacing the rocker panel part completely. Since they are having a hard time finding the part. [re: How would you go about repairing this on a 2013 Honda Accord?]”
“You're more than likely going to need a factory rocker panel replacement, up into the dog leg as there is alot more to it than just the outer layer. Check with local salvage yards like LKQ. They can cut out a piece on a non rusted vehicle that you could then cut out the cancer on yours and trim to fit the used part. A welder and welding experience, as well as corrosion knowledge is needed, then the paint side after. [re: How would you go about repairing this on a 2013 Honda Accord?]”
“To answer both questions. Wavy wire as mentioned in another comment would also work. But no pre made tabs aren't a thing. It would be a piece of scrap or some sheet steel that you cut. Preferably fairly thick. .050 or better. As far as a ram to pull that's how most frame and heavy repair is done. Typically you use a chain and pulley. If it was on a frame rack it would be straightforward. On the floor you would need something to secure the ran down to the floor as well as an anchor point”
“Just buy aftermarket replacement rockers. With a little fitting they are fine. Better than you have now.”
“Wire wheel, or paint / rust stripper wheel. Check structural parts for anything obvious. Spray with fluid film, surface shield or similar. I'd put some in the rockers, and into the bottom of the doors, trunk and hood too.”
“Depends on what it looks like underneath, if it is not bad, I would patch, make my own rocker and inner.”
“Yeah for sure rockers can be repaired. Most common rust repair performed on any vehicle.”
“Fluid film will stop the rust where it’s at. You’ll need to spray inside the rockers, doors, frame and other cavity’s. If you want to really do a nice job, wire wheel the frame to remove loose rust, then sand, then use a paint over rust product. If that’s too much work, then just fluid film and be done. For the rust bubbling under your paint, you’re stuck with that unless you sand it off and repaint. I’m in Winnipeg so I know all about road salt. I fluid film all my winter vehicles.”
“I’m in Saskatchewan yeah. I’ve already put a lot into it to bring it back to life I don’t know much about rust and just thought the pinch welds rot out and that’s normal for here. I’m not a mechanic or anything I do small work on it myself but that’s about it. I’ve put $1000s into it because it has a 3.8 series 3 and now im feeling pretty damn bad about it.”
“You mentioned that repairing the inner rocker itself isn't particularly difficult, although the back of the outer rocker also looks badly rusted. If you were repairing this yourself, what would a proper repair actually involve based on what you can see here? How far would you expect to cut back, what would you want the replacement metal welded to, and would the outer rocker/floor area need to be opened up as part of the job? Also, if you were inspecting somebody else's completed repair a”
“From what we can see here, it could be pretty localised, rockers can trap dirt and water, and sometimes the rocker drains block which massively speeds rust. The difference between the rockers and frame rail here is enormous. So that's the actual answer, you need to know the condition of the whole car. Your local inspection regime matters too- here, it wouldn't pass, not even close. But welding the rockers is a pretty simple job, and if the rest of the car is solid then fluidfilm or simil”
“Ah, okay, that makes sense, I thought I was looking at a front fender and couldnt figure it out. Rear quarter rust is a bit worse, as it is part of the unibody and continues directly into your rocker panels. And on a van with a sliding door, this might be an even bigger issue, because the bottom of the door rests on a rail that is mounted in top of the rockers. So you need to check how close that is to the rust area, otherwise you might get some issues whenever you fully slide the door to the ba”
“In the UK it would. Everything has to be welded on the sills/rocker. I would go online and check out your regulations.”
“Thanks for the positivity- Where the frame meets the inner rocker panels does that need to be fixed to pass inspection?”
“I recently ran into a F-250 the engine and transmission is top notch and in good condition, the issue I’m running into is the rust. I realize I need new rocker panels (inner and outer) but my concern is where the underbody meets in the inner rocker panels, they seem completely rotted out on the ends, the frame in the middle is good condition, just not where it attaches to rockers. Will this fail inspection and could someone offer some recommendations on simplest way to fix/bandage. Also I have l”
“Yeah looks like it’s just the outer rocker. Would need to straighten out first before installing side skirts”
“Went over a curb about a week ago and wanted to know what the best course of action would be to repair such a thing. I was thinking of sanding this out and putting some rust inhibitor over the scratch and the just putting a adhesive rocker panel cover over it to cover it. I'm on a bit of a budget for the time being and can't really spring a 1500 dollar repair bill atm. Any thoughts or suggestions would be greatly apprieciated. submitted by /u/Fatdix69 [link] [comments]”
“Hello all, I purchased a 2017 WRX STI for a project car. It had been sitting in a gravel parking lot for the last 3 years with a blown engine. The inside of the rocker near the driver side rear wheel is starting to look pretty rotted. Curious of what your opinions are on the matter. Appreciate any info and feedback. submitted by /u/dak0399 [link] [comments]”
“There are air tools that can bend small flanges for lap joints as well as punch holes for plug welding... Or I use a bead roller with step dies to do stepped flanges however big I want for lap joints. That pillar looks like a hell of a project in itself... Like how is it that rusty? Usually you try to start with a decent car and just fix the few spots..”
“As I said with the B pillar straddling this joint, the rocker to floor channel brace straddling this joint, and the body having a "mount" of sorts resting on a crossmember at this joint, plus new floor pans for whatever rigidty that adds tying much of this together... well I can't imagine a way I'd reassemble this that would be cause for concern. What method of repair do you have in mind that is concerning considering all this as shown in the last picture? How would you repair”