Rocker panel repair

[Booger]

After Booger got a new fuel line and electric fuel pump I looked deeper into rocker panel damage.  Previous owner filled foamed spots (good).The project mostly cosmetric some spots tack weldable, just a cover plate, if you will. does one use bare steel or use galvy sheet metal and pop rivets? All undercarriage

Edited May 18 by Booger
spel

[Plymouthy Adams]

as a quick patch yes, as a repair....no

[Los_Control]

29 minutes ago, Booger said:

does one use bare steel or use galvy sheet metal and pop rivets? All undercarriage

Not sure I understand your question ..... original rockers were all steel. ..... Offers a fair amount of support for the A pillar and floors ...... should be welded imho, not riveted.

 

Not sure I understand the po used foam for a internal filler on the rockers?

I'm afraid if you try welding to the rockers with foam as a backing .... the foam will catch fire and burn very hot .... unless it is a a fire retardant foam of some sorts .... I doubt it.

 

Again let me say I do not understand your question ..... If the PO sprayed in some sort of foam to protect the rockers ..... I would be worried about it being flammable ... rivets might be the better choice here ..... although welding in patches would be superior.

[Eneto-55]

The rocker cavities are designed as an escape route for moisture.  Foam will stop that, and thus cause rust issues. (Maybe pour some lacquer thinner in there - should dissolve it.  But if they also closed up all of the weep holes, then maybe leave it?)

[Booger]

I think Ill start with digging out some of that foam and test it to see how flammable it is

[Los_Control]

Thats why you get paid the big $$ ..... excellent idea. At least find out what you are working with.

 

Probably depends on what year they sprayed the foam in ..... todays market most would not be flammable.

If it was done in the 70's-80's .... good chance it is.

 

In construction we used a typical cheap brand called great stuff .... It really was great stuff to have around.

To pass fire code, every protrusion where holes were drilled in the framing for pipes or wires, the holes were then foamed so a future fire could not get air or the fire could not spread  to the next cavity through the hole. .... It's job is to prevent fires, along with insulation in cracks,windows & door frames etc....   So it would be difficult to buy flammable foam.

 

In the early days when it was just used for insulation, all bets are off.

[Booger]

ok 20 gauge mild steel is what Im going with

[Los_Control]

Sure you do not want 18 gauge?

 

20 will work I guess ..... the rockers do offer some structural support .... A & B pillars connected to the floor ..... just a patch 20 will be fine.

 

20 is a real pita to weld because it is so thin. Modern cars use 20 gauge ..... the replacement floor pan in my 49 Dodge truck is 20 gauge.

 

I have welded 20 gauge several times in the past and feel comfortable welding it .... I just kinda cringe when I think about a upcoming job using 20.

I dreaded just thinking about welding in my floor pan ... just have to be extra careful and adjust your welder properly and take your time.

What welder do you have?

 

Just if it was 18 gauge I simply would not give it a 2nd thought. and if I had a choice I would choose it.

[Frank Gooz]

i am in need of parts or Trying to make my Owen that is a scary thought 

After Wayne passed i have seen or heard of no one making parts for our cars

is there someone ?

 

Frank

[Plymouthy Adams]

the ones you get are made on a brake and common bend and thus the J is missing and also many do not realize the slight curve is supposed to be in place along the length.....these were pressed units, I have only found one set of NOS factory panels.  I have bought from some companies that the units were pure junk, others that were usable but again, there is no true J and not seen the proper curve in the P15's either.  BUT knowing up front the short comings, you can do a good job taking your time correcting on the fly when welding in.   If you need a full rocker, yes buying one is a good start....if just a patch here or there...short section of the rockers is a relatively simple task.    DIY does show the curve in their product, the do not show a J as to the correct box..cannot speak for that as I have not used their items.  But currently there are three sellers on e-bay now. (suspect one company is selling under two names)

[Los_Control]

I feel if you want to start welding in patches, it is time to start learning fabrication. Really not hard for the basics.

I really like this video to make a pipe anvil. While I do not know the extent of your rusted panel, the basic curves can be made at home.

I will post the video below, just showing my version of it .... I do not have room in my tiny space to make the full sized version.

 

 

I do have a smaller round pipe .... I can unbolt and bolt it in place .... I have some 4" pipe, to be honest I just never needed it yet.

If I insert metal into it as is, then pull back on it, I can make a 90 degree bend you might find as a pinch weld on the bottom of the rocker.

 

Then you reset it and push forward and start working a gentle curve .... sometimes a larger pipe helps make a softer gentle curve, the smaller one makes a tighter curve .... you get it .... just junk lying around the shop welded together and you use it as a tool.

To be honest, the 3/16" x3' angle iron I have is too flexible for a 90, so I draw a line on the metal , insert it to the line then clamp it down .... works perfect.

 

This photo is really sad .... just showing that I actually fixed this while newer thinner ones were available ..... I needed the practice.

I think I counted 13-15 individual small pieces welded together .... that is how you take care of complicated pieces like the dog legs of the pillars welded to the rockers.

Not difficult or scary, just time consuming. .... Take your time you will be fine.

 

Every body patch in my truck came from a old school that had some 18 gauge metal shelves missing the legs ... I paid $5 for it ..... Although I do have some thicker metal for braces and such.

 

Once you start bending and creating patches ..... it is almost addicting .... just kinda fun and you're sad once the paint is on and no more panels to create