Previous Article | Next Article

Body Repairs: Rocker Panels

The rocker panels on the 40 run the length of the car from the forward body mounts to the wheel wells. At one time, the original rockers on this car had rusted out and, to repair them, someone simply welded some new sheet metal directly over the rusted out portions. As they worked toward the rear of the car, they must have discovered fiberglass, because that is what they used to repair the sub-rails and the trunk floor. Anyway, both rocker panels had to be replaced, which is not a simple task.


Enlarge
Enlarge 		 
Removal

This removal procedure assumes that the floor needs replacement. Usually, if the rocker panels need replacing, the floors will also need to be replaced.

This is how I suggest removing the rocker panels:

  • Brace the door openings horizontally or diagonally
  • Cross-brace the body at the B pillar and the A pillar
  • Unbolt one side of the body from the chassis, raise it about 6 inches off the frame, and support it on jack stands.
  • Drill out the spot welds where the rocker panel is welded to the bottom of the forward body mount, the bottom of the B pillar and the quarter panel.
  • Use a plasma cutter, Sawzall or cutting wheel to cut the floor away about 6 inches from the old rocker panel
  • Remove the rocker panel


Enlarge
Enlarge 		 
B Pillar Bottom

The bottom of the B pillar sits on the rocker panel, so if the rocker was rusted out, the bottom of the B pillar will probably need patching. The left side just needed some cleaning up but the right side B pillar needed some patching and a new bottom.


Enlarge 		   
Installation

Much like sill plates in home construction, rocker panels provide the foundation for the entire body and they have to be installed correctly or the car will be crooked. Replacement rocker panels come in two parts; a forward piece and a rear “sub rail”. The front part goes from the bottom of the forward body mount to the front of the rear-most body mount. The sub rail goes from outside the rear body mounts and then curves in and up to the wheel wells.


Enlarge 		   
The replacement rocker panels didn't quite match the profile of this chassis, so they had to be pie cut, bent to fit, patched and then re-welded. They also need to have holes drilled for the body bolts. There are two at the front body mount, one at the B pillar and two at the rear body mount.

The sub-rail is welded to the forward section behind the rear body mount. The sub rails also required some cutting, bending and re-welding to fit properly.


Enlarge
Enlarge
Enlarge
Sources

Bob Drake: http://www.bobdrake.com

EMS: http://www.emsautomotive.com

McPherson's: http://www.mcpherson.com

© 2001-2005 Chariot Software Group

Project 40 Home | Section Home