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Inner Rocker Panel Replacement; Outer Now? Deeper and Deeper

Jamie Chriss

Jamie Chriss

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Feb 28, 2015
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Why not spend the money and buy a complete platform, something solid to build off of?
I am always concerned about the integrity of the metal with all that Swiss cheese.
 
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ObscureMachine

ObscureMachine

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So there is one spot on the outer rocker, on the bottom - a bit about 2" x 5" that is rusted pretty bad. I'm not replacing the outer rocker. I'm just not. I don't have the time as this is really my daily driver. So I ordered a rocker panel and i'm going to graft in the small section that is rusted.

Jamie, pretty much everything that has rust is being replaced. One day I'll have to replace the front door Passenger door post, but I'll do that when I pull all of the front apart, what I call Phase 4
 
Rustytruck

Rustytruck

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The outside rocker is 2 pieces. I separated the 2 pieces keeping the old flange on the door sill on the old top piece and keeping the new flange on the new lower piece then stacking the 2 flanges and welding the lower in. That gives you a really clean lower rocker without fudging the top. its easier than patching part of the lower rocker and having to do the body work on it later.
 
74 Bronco Billy

74 Bronco Billy

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So, measured 10+ times, put the door on the hinges 5-6 times, finally got it to fit fairly well. SO, time to burn in.
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Jamie Chriss

Jamie Chriss

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I get it, I am not casting judgement, summer is coming and you just want to get out and enjoy the day. Good work, I am so far from driving my truck it isn't funny.
 
74 Bronco Billy

74 Bronco Billy

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Jamie Chriss said:
I get it, I am not casting judgement, summer is coming and you just want to get out and enjoy the day. Good work, I am so far from driving my truck it isn't funny.
Click to expand...
It'll be 2 yrs come father's day that I got mine. Just keep plugging along. I take pride on the little advancements, then try to plan out next step before I step back too long and start pondering.
Right now pondering how I am going to mount these too.
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ObscureMachine

ObscureMachine

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If (I can't believe I'm actually thinking about doing this) I pull the outer rocker, which do I put in first, the inner and line everything up? or the outer, then attach the inner? What are the measurements I need to check to get the opening right?
 
74 Bronco Billy

74 Bronco Billy

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ObscureMachine said:
If (I can't believe I'm actually thinking about doing this) I pull the outer rocker, which do I put in first, the inner and line everything up? or the outer, then attach the inner? What are the measurements I need to check to get the opening right?
Click to expand...
If you pull the outer, then put inner back in 1st, then outer. Has to do with all those 90 degrees on the inner rocker. You do NOT want the outer rocker done 1st like I kept in place. PIA to put inner roclrr in place if outer is still there in the way.

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ObscureMachine

ObscureMachine

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74 Bronco Billy said:
If you pull the outer, then put inner back in 1st, then outer. Has to do with all those 90 degrees on the inner rocker. You do NOT want the outer rocker done 1st like I kept in place. PIA to put inner roclrr in place if outer is still there in the way.

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Click to expand...

That's what I thought. You've been a huge help Forrest (2 "R"s?)! I'm terrified I'm going to run into something I don't want to see when I putt it.

I have it braced near the top of the door opening. All the crossrails are disconnected or out. Is there anything else I need to weld in a brace to hold? - jim
 
74 Bronco Billy

74 Bronco Billy

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ObscureMachine said:
That's what I thought. You've been a huge help Forrest (2 "R"s?)! I'm terrified I'm going to run into something I don't want to see when I putt it.

I have it braced near the top of the door opening. All the crossrails are disconnected or out. Is there anything else I need to weld in a brace to hold? - jim
Click to expand...
Jim,
Put a brace in to hold the front A pillar and rear B pillar in a straight line so there's no movement in door plane nor tangentially. If you can, put a brace to the outer kick panel.
You may want to put in those cross rails that are bolted to frame to line up inner rocker on that side.
Take measurements of the height of floor, inner rocker, outer rocker to the top of opening, 3 place across door. Make sure you are level to begin with.
Forrest
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ObscureMachine

ObscureMachine

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I'm starting to freak out. ?:? :mad: :cry: Remember, this was just supposed to be a floor pan and I need to be driving it in June!

Did some digging around the front passenger door pillar and this is what I found. Can I fix any of this without pulling the front fender?

In the one pic with the red area circled, are those pieces behind (towards the front of the bronco) attached to the fender? What do they originally attach to? Does that make sense? What replacement part would that be?

Pray for me. - jim
 

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74 Bronco Billy

74 Bronco Billy

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It looks like you cut from inside out. That pillar is in sad shape. Is the metal flaky with no strength, or just rusty and can be cleaned up.
Here's pictures from the outside, fender removed. I cut into my pillars, found more than I bargained for, and am replacing in Toto. But, I could have cleaned off the rust, painted por 15, and patched closed.
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