Auto body repair & detailing: Rocker Panel Removal, seam weld, chevy truck


Question
Ihave a 1966 chevy truck that I am wanting to replace the rocker panels . After drilling out the welds what else is involved in removing the rocker panel?

Answer
First, have the new panel in hand. Use it to help decide where to cut the old one out. You will need a sawzall, or better yet, a small air reciprocating saw. A cut off tool with cutting discs will work, but I hate the sparks they throw everywhere. If you are replacing the cab corner, the rocker will need to go in first. They tend to be placed underneath the cab corner. If not, you will need to cut off the rocker at the cab corner seam, and trim the new rocker so it will slide underneath. You will need to remove the door for access around the bottom hinge, and probably remove the fender. Overlap the new rocker, at the hinge pillar, about a half inch. Drill 5/16 holes about every inch across the top, then drill holes about every 1-1/2 inches across the bottom and top pinch weld areas. You re- attach this panel by plug welding these holes.  Seam weld across the top (at the hinge pillar) to finish. Now, before doing any welding, re-hang the door to be sure the new rocker is properly fitted. Adjust as necessary, and weld her up. Take your time don't over heat the panel. Bill