Inner Rocker Panel Replacement; Outer Now? Deeper and Deeper

ObscureMachine · Apr 8, 2018

About to tackle replacing the passenger inner rocker panel. Outside Rocker is in good shape except for one small spot I can patch.

Anyone have pictures, a build thread, youtube video, anything VISUAL to give me some wisdom? I have a new panel, just want to do it right.

Thanks- Jim

Master Chief · Apr 8, 2018

Jim,

Sorry, nothing visual.

Get your Bronco high enough so you can work comfortably underneath it and remain clear of any hot slag that will drop while you weld. There is almost nothing worse than having a ball of molten steel rolling around inside of your clothes. It will burn anything and everything it touches until it cools. Think hornet nest x 1000.

Use a flap wheel to clean off the old paint and expose the welds then drill them. Remove the old panel, treat the entire back side of the outer rocker for rust prevention, treat the inside of the new panel you are installing, and weld in the new piece.

Roger

74 Bronco Billy · Apr 8, 2018

ObscureMachine said:
About to tackle replacing the passenger inner rocker panel. Outside Rocker is in good shape except for one small spot I can patch.

Anyone have pictures, a build thread, youtube video, anything VISUAL to give me some wisdom? I have a new panel, just want to do it right.

Thanks- Jim

I am exactly in the same spot. Here's some pictures. I used the plasma torch to cut it out after I loosened up all the spot welds. I cut thru the outer rocker because I plan to put rock skis on and some type of reinforcement steel inside. Have at it. It is a pain in the butt. Go Redemption!

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74 Bronco Billy · Apr 8, 2018

Make sure you take measurements from above and on both sides. I also used a degree wheel to measure all metal to see if it was level before I removed it. Most was 0 degrees, but it seems my door posts tilt in 1.5 degrees at the top compared to the bottom.
X1000 about slag getting in your clothes. I was once welding over my head on a ladder, fireball went into my pocket. I was wearing long under wear. I almost fell off ladder, I had burn holes half way down my long under wear, and still have small round bb scars to prove it. THAT sucked.

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AZ73 · Apr 8, 2018

Start at post 65

http://classicbroncos.com/forums/showthread.php?t=217635&page=5

The major hints are BRACE the body, coat the inside while you have it apart, and don't forget the drill out the spot welds on the floor braces where they attach to the inner rocker.

Master Chief · Apr 8, 2018

74 Bronco Billy said:
X1000 about slag getting in your clothes. I was once welding over my head on a ladder, fireball went into my pocket. I was wearing long under wear. I almost fell off ladder, I had burn holes half way down my long under wear, and still have small round bb scars to prove it. THAT sucked.

I bet that was one hell of a dance Billy. I was rolling around my garage floor trying to escape the cause of the pain and still have scars along the left side of my torso from it.

Roger

74 Bronco Billy · Apr 8, 2018

Master Chief said:
I bet that was one hell of a dance Billy. I was rolling around my garage floor trying to escape the cause of the pain and still have scars along the left side of my torso from it.

Roger

I was so lucky not to fall off the ladder! 14ft in the air, shaking my leg, dropped the electrode, my little bro learned some new cuss words. NOT my best moment, but I sure learned that lesson.

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suckerpunched · Apr 8, 2018

heres a few I have from when I did mine

74 Bronco Billy · Apr 8, 2018

suckerpunched said:
heres a few I have from when I did mine

Nice patches SP.

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henry d allen · Apr 8, 2018

i wood try to patch it i like to do floor pans and inner and other rocker at the same time comes out and in better plus u no you good they in that spot for many more good years of riding

Bronco Paul · Apr 9, 2018

ObscureMachine said:
About to tackle replacing the passenger inner rocker panel. Outside Rocker is in good shape except for one small spot I can patch.

Anyone have pictures, a build thread, youtube video, anything VISUAL to give me some wisdom? I have a new panel, just want to do it right.

Thanks- Jim

Hi Jim,
Here’s the repair thread on mine:

http://classicbroncos.com/forums/showthread.php?t=215209

If you look towards the bottom I run through step by step. Hope it helps!

Paul

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ObscureMachine · Apr 10, 2018

Thanks everyone! This is most helpful!

One question. I haven't removed the #1 and #3(front of bed) crossrails. The # 2(seat platform is out) How hard is it going to be to replace this without removing those crossrails?

74 Bronco Billy · Apr 16, 2018

It ain't easy, but what is on a Bronco, right?
Just use the plug cutter judiciously, use a bright light to find all the pieces that are attached. I look for dimples from the spot weld, Mark it with a sharpie, drill pilot hole, use plug weld cutter, and tease out the rusty panel or support, usually in pieces.

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ObscureMachine · Apr 17, 2018

Thanks for all the pics and advice. I'll update on how it's going. - jim

ObscureMachine · Apr 18, 2018

Does anyone have any pics of removal of passenger side inner rocker, specifically where the #3 crossrail attaches just around the door post?

ObscureMachine · Apr 18, 2018

Passenger side rocker situation. The inner rocker has to go. I was hoping I could patch the outer rocker (at the sill plate). But now as I look more......

Do I need to just go ahead and replace the inner AND outer rocker panels. Not a show truck, but I want it done right, or as right as my skill set will allow. The pics may not make much sense. They are 1) a little of the rust on the bottom of the outer rocker. 2) a few pics of the inner rocker where it meets the #3 crossrail. In front and one from the rear. 3) "Door sill".

Would it be easier just to pull everything or just do numerous patches?

suckerpunched · Apr 18, 2018

honestly I think you should change them. the rockers themselves are pretty easy to change but what usually happens is once you get that off you find out the inners are bad. door posts, strikers, floors need patching. sound familiar? you kind of did the reverse, but since they are already almost off, just change them. If you wanted to you could probably weld some of the other stuff (inner rockers, floor and cross braces back in to hold things in the right place before you cut em loose.

It's probably easier too.

rspd505 · Apr 18, 2018

Another thing to do, is use self tapping screws to test fit panels before welding. That way you can adjust things if needed.

ObscureMachine · Apr 18, 2018

Hmmmmm..... I think I'll start a side thread to look for threads about this

74 Bronco Billy · Apr 22, 2018

I replaced only the inner PS rocker, but had to cut out a slice of floor board at the rear to slide it downwards as the inner rocker panel has a 90 degree bend. I will patch floor or cover with bracket that holds B pillar. Painted the insides with Por 15 last night.

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Inner Rocker Panel Replacement; Outer Now? Deeper and Deeper

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