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Old May 21st, 2007, 11:46 AM   #1
xj4life
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Default XJ Rocker Panel Replacement

I'm not going to go through a lot of fine details on this one as there are already a lot of good write ups on this. I'm just going to show my spin on it.

I used these two write-ups for reference:

http://www.myxj.net/blog/?p=13

http://projectxj.com/mods/rocker.replacement.htm

I didnt want to do the same old rectangular tubing replacement. I wanted something that would allow me to boat side my XJ in the future if I decide to go that direction. I also wanted to make sure I tied the rockers into my interior cage and the "frame".

Here's what I started with on the drivers side


Here's what I started with on the passenger side


A little massaging on the passenger side to straighten it out some


Here's the new rockers (upside down). 2"x4"x3/16" as the base, 1.5"x1.5" angle to weld to the pinch seam, and 4"x1/4" plate to finish it off. Ends were capped when done and all exposed welds were ground smooth.


Cage tie-ins at the A and B pillar (1.5"x0.120 tubing, same as cage)



Frame supports (1"x2"x1/8" - 4 places). Eventually I'll be plating the frame and hopefully adding a sheet of 3/16" plate over these to boat side it.


Finished pics, unpainted



I took one hit to them on the drivers side this past weekend on a rock. Not a real hard hit but enough to wake me up. No damaged at all to them except scratched paint.
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Old May 21st, 2007, 01:57 PM   #2
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Looks great!

How much to do mine for me?
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Old May 21st, 2007, 03:45 PM   #3
Blue XJ
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How'd you do the cage tie ins? Weld the tube to the rocker reinforcement, then cut a big hole in the sill and push it through and weld to the cage?

Wanna do mine next time I'm out that way?
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Old May 21st, 2007, 04:14 PM   #4
Dave Kerwin
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how did the passenger side go with all that carnage?

did you consider making them stick out a bit further than the body to prevent further damage?
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Old May 22nd, 2007, 09:36 AM   #5
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Quote:
Originally Posted by Blue XJ View Post
How'd you do the cage tie ins? Weld the tube to the rocker reinforcement, then cut a big hole in the sill and push it through and weld to the cage?

Wanna do mine next time I'm out that way?
ahh considering it took me about 40hrs to do mine we'll have to see. most of that time was repairing body damage. but we gotta get your cage in first.

cage tie-ins were a nightmare. i used a hole saw to go through the inner rocker. then used a sawzall to cut a flap (flaps were bent back when all finished). tack the tubing to the new rocker and see if it all lined up. made adjustments and final welded them to the rocker. then once the rockers were all set welded them to the cage and welded the rockers to the body. the frame supports were added once that was all done.

Quote:
how did the passenger side go with all that carnage?

did you consider making them stick out a bit further than the body to prevent further damage?
passenger side took a majority of the time. i tried my best to get it straighted out. the pinch seam wasnt damaged to bad but the door sill/B-pillar were a mess. I think there is still almost a 1/2" bow in the door sill.

some time soon i'm going to add either round or square tubing to get me a little further away from harm. i had planned on doing it this go around but ran out of time. tubing can easily be added in the future.
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Old May 22nd, 2007, 09:47 AM   #6
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Nice job, I like!
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Old May 22nd, 2007, 11:44 PM   #7
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Vary sweet looking job..
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Old October 30th, 2009, 02:14 PM   #8
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quick update. so far they've held up great to some really hard hits. keep meaning to add some tubing to them to keep the body away from things but havent had the need to. though i also dont care about body damage.
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Old October 30th, 2009, 04:23 PM   #9
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I've been thinking about this for a while now... how much of the door sill did you leave? I just wish someone would make a pre-bent box like that...
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Old October 30th, 2009, 04:30 PM   #10
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i left pretty much all the door sill. cut on outside vertical face, if that makes sense. you can see it in this pic

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Old February 26th, 2010, 12:27 PM   #11
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just found this...nice


Black Box Fab ftw !!
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Old February 26th, 2010, 01:17 PM   #12
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H'mm wonder how these would look/work on my tow rig?

My 96 dodge diesel is in need of rockers (rust).
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