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Old April 6th, 2012, 09:20 PM   #1
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Default Rusty rocker panel fixes- fullsize chevy

So as with every other chevy/gmc owner, my rocker panels are rusted, they're not completly gone but they're still rotted and look horrible. I know that the best bet would be just completly replacing the rocker with a patch panel, but what about just getting rid of all the rot and using fiber filler and such? I've seen some pretty good jobs with fiber filler and body filler. Any tips or good how to's for novice body guys?

The only reason why I havne't just planned on getting a patch panel is because I have neither the proper tools nor skills to put a new panel on and the only real place that's around me is the dealership for body work.

Any good guys for body work up north that anyone knows of?

the cab corners are still solid but i'm sure they're rotting on the inside too.
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Old April 6th, 2012, 09:59 PM   #2
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Lots of filler + no good spot for it to stick to + bumps = broken pottery


In my experience filler just cracks and falls out, i usualy just paint the rocker black and call it good.
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Old April 6th, 2012, 10:02 PM   #3
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Lots of filler + no good spot for it to stick to + bumps = broken pottery


In my experience filler just cracks and falls out, i usualy just paint the rocker black and call it good.
I gotta do something with it, rust really doesn't sit well with me for my truck. It's not the greatest mall queen but I take care of it and use it like a truck. I can deal with some scrapes and a ding here and there, but straight rot is a no go

If I leave it then the truck will go from a nice looking pavement pounder to a rusted out POS with big tires
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Old April 7th, 2012, 07:55 AM   #4
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really rednecky but it works well.........
fill rocker with expanding foam, when cured, trim off excess with steak knife, dig/drill into foam to anchor fiber filler, apply long strand filler being sure to get it into anchor areas, sand and paint with your color. I (shamefully) did this on an 89 crew cab with really long rockers and it worked/looked good for about 4 years before it started breaking up.

Last edited by Gr8wht2000GMC; April 7th, 2012 at 07:56 AM. Reason: spellcheck
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Old April 7th, 2012, 08:08 AM   #5
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Duct tape and herculiner. Ask SNDVIPR, his wife's XJ was done that way with the rockers. He didn't know about it until later when he was doing something else and put his hand thru the rocker.
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Old April 7th, 2012, 08:15 AM   #6
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I've seen the foam trick. It seems like a decent idea for a quick n easy. Cool to know that it can last that long. I personally dont mind rust.
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Old April 7th, 2012, 08:20 AM   #7
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It has been a long time since I saw this on one of the hot rod shows, but they cut away the rusted out cab corners and glued on the replacement. As a chevy owner I will be looking into this as well.
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Old April 7th, 2012, 08:28 AM   #8
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Yes they do make a glue for patchs its right around 40 buck for a tube and uses a calk like gun to apply it
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Old April 7th, 2012, 05:13 PM   #9
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It has been a long time since I saw this on one of the hot rod shows, but they cut away the rusted out cab corners and glued on the replacement. As a chevy owner I will be looking into this as well.
I'll have to look in to that, seems like something I might be able to do

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really rednecky but it works well.........
fill rocker with expanding foam, when cured, trim off excess with steak knife, dig/drill into foam to anchor fiber filler, apply long strand filler being sure to get it into anchor areas, sand and paint with your color. I (shamefully) did this on an 89 crew cab with really long rockers and it worked/looked good for about 4 years before it started breaking up.
Heard that trick from many a person, but i'm not sure I really wanna do that much of a redneck ninja rig lol
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Old April 9th, 2012, 12:19 PM   #10
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A lot of the XJ guys just cut the rust out and weld in some steel rails for protection and to act as new rockers. Might work for you...
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Old April 9th, 2012, 08:02 PM   #11
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A lot of the XJ guys just cut the rust out and weld in some steel rails for protection and to act as new rockers. Might work for you...
Don't know if that would work, there isn't really anything to weld to other than the body panel
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Old April 9th, 2012, 09:03 PM   #12
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Just fix it right or leave it rusty. A half az repair makes you and the truck look like crap.

I have used the 2 part "glue" before when repairing/replacing sub compact floor panels. It does work and provides a very stable and bond. But, what your talking about is placing a panel over top your existing rocker. People will notice that cob job from 30 feet away. I know cause I have done it. I drove around for 2 weeks with it before finally ripping it off causing more damage. I simply ordered rocker replacements after that and fixed it right.


You can use a "hobby welder" to weld rockers on.

It is not complicated to repair rockers. If your squeamish practice on a junk fender or 3/4 panel. That's what I did when I was 8. I must have went through 8 junk fenders before I laid down a weld I was happy with.

You can order the replacement rockers, Make a temporary bolt in brace so your cab does not tweak, cut out the area, and drive it to a welder. 30 minutes or less later your new rocker will be welded on. Take it back to your house, sand, prime, color match, and paint or undercoat both sides.

There has to be a welder somewhere around you.
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Old April 9th, 2012, 09:26 PM   #13
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I haven't seen it done in many years but welded wire used to be great for doing rockers. you could just roll it to the shape you wanted then push in the bondo to make it stay.
now a days I could see doing the wire plus foam to make a base. should be strong and take bondo well.
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Old April 10th, 2012, 10:38 PM   #14
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Quote:
Originally Posted by cerial View Post
Just fix it right or leave it rusty. A half az repair makes you and the truck look like crap.

I have used the 2 part "glue" before when repairing/replacing sub compact floor panels. It does work and provides a very stable and bond. But, what your talking about is placing a panel over top your existing rocker. People will notice that cob job from 30 feet away. I know cause I have done it. I drove around for 2 weeks with it before finally ripping it off causing more damage. I simply ordered rocker replacements after that and fixed it right.


You can use a "hobby welder" to weld rockers on.

It is not complicated to repair rockers. If your squeamish practice on a junk fender or 3/4 panel. That's what I did when I was 8. I must have went through 8 junk fenders before I laid down a weld I was happy with.

You can order the replacement rockers, Make a temporary bolt in brace so your cab does not tweak, cut out the area, and drive it to a welder. 30 minutes or less later your new rocker will be welded on. Take it back to your house, sand, prime, color match, and paint or undercoat both sides.

There has to be a welder somewhere around you.
I originally didn't have a welder, but i picked up one that is just a hobby welder basically. I've always been reluctant to weld on a body because my welding skillz aren't that great to begin with and I don't want to end up with something that looks crappier than what I started with.

I think i'm just gonna give it a shot, at least it's on the bottom of the truck which isn't right in the line of sight like a bed side would be. I have to order a couple rocker replacemnts and go from there
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Old April 10th, 2012, 11:51 PM   #15
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Chris you forgot I have a welder huh? I've been building and Welding my frame and body of the Toyota, and I was a welder at Benjeys, did lots of sheet metal work...I think we could work something out to do it the right way man.
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Old April 10th, 2012, 11:51 PM   #16
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And i only live 5 mins from you.
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Old April 11th, 2012, 10:25 AM   #17
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Quote:
Originally Posted by Gr8wht2000GMC View Post
really rednecky but it works well.........
fill rocker with expanding foam, when cured, trim off excess with steak knife, dig/drill into foam to anchor fiber filler, apply long strand filler being sure to get it into anchor areas, sand and paint with your color. I (shamefully) did this on an 89 crew cab with really long rockers and it worked/looked good for about 4 years before it started breaking up.
That foam retains a TON of water. When I had to redo my boat, and was tearing off the old floor, the pevious owner filled many of the cracks with that great stuff. Not sure I'd want all that soggy foam in there.

If you cant get someone to weld new panels in, you could always prep the old spots with rust transforming paint to seal it all in as much as you can (if you dont want to cut it out) and then rivet replacement steel in place and bedliner it or something.
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Old April 11th, 2012, 01:45 PM   #18
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Quote:
Originally Posted by Yotabalt View Post
Chris you forgot I have a welder huh? I've been building and Welding my frame and body of the Toyota, and I was a welder at Benjeys, did lots of sheet metal work...I think we could work something out to do it the right way man.
And, yep....I did not even think of that

I'll need to bring it over maybe this fri (4-13), and we can get a plan figured out?
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