Step down rocker fix

bent metalbent metal Posts: 1,512Senior Contributor

Step down rockers seem to like to rust out.  The factory stuffed some sound deadening steel wool looking stuff inside the sheet metal frame rail.  So a lot of times you will look behind the outer sheet metal and find it's rusted through in the structural part.  This car was to be driven and the owner liked the patina look.  But he wanted the car to be structurally sound.  He asked me to not restore every detail.  Just make it whole again.  With these, I adjust the door first.  Once the door is right and opening and closing like it should, then I support the body just ahead and behind the repair.  My "control" reference is the door opening and closing correctly.  Now I can start cutting.  Make sure through the entire process that door stays right!  If it moves, something needs to be addressed.    

Comments

  • bent metalbent metal Posts: 1,512Senior Contributor
    More of this car.  I think the silver one was a different car.  I liked the green and purple one, it was a little hot rod that looked to have no remorse.  
  • bent metalbent metal Posts: 1,512Senior Contributor
    Now we get into the tricky stuff. The 1954's.  In '54 they welded the rockers on.  I have had people bring me stuff and say, "Just weld up the pin holes."  I have to explain to them that we are only seeing the worst of the rust.  The rust is coming from the inside.  What we are seeing is where the rust has gone all of the way through when we see pin holes.  The rest of the panel is rusted half way through, or worse, all along the inside of the panel, where we can't see.  Did a little repair under the step plate and into the A-pillar to get warmed up. :) Notice the factory drain in the floor.
  • bent metalbent metal Posts: 1,512Senior Contributor
    Line up the door first.Cut out new rocker, some shaping required.Patterns and templates before any cutting on the car.A little worse once you really start to get into it.I cut loose the rocker and pulled it down.  Notice it's rusted from the inside.  Also, see the steel wool looking stuff inside the frame rail, still there, and the focal point of the rust in the sheet metal frame.  Below, primed inside before it gets welded shut.
  • bent metalbent metal Posts: 1,512Senior Contributor
    This is all of the stuff cut out.  He had an earlier door on the car, until he could find a good '54 door.
  • cchancelcchancel Posts: 48Member
    This is great stuff! Please keep it coming.
  • bent metalbent metal Posts: 1,512Senior Contributor
    I have done some patch panels for cars too.  Although it's better to have the car when making these, especially since the skirts fit so tight in the wheel opening in 1954.  The new panels should be fit to the body as you go along.  But, that's not always possible.  So these were made in house and sent to the car.  I forgot to take pictures of the rockers. 
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