2nd Gen rear rockers rust thru-What to do?

[Dono]

Hi Guys,
Looking for advice here. Have a look. I don't own a welder. I understand you can use a speciaal 2 part epoxy to bond metal to. Can I get replacement rear panels, or should I form some metal? Both sides will need attention.

 

[Dono]

ok, so this is a dogleg panel. My trucks getting old. Nothing like this available locally anymore. raybuck.com seems to have them, but their web site doesnt allow shipping to Canada. Sure would like to find this locally.

 

[Dono]

Ok, this sites awesome(Searching and reading). Crosscanada parts can still get them ($60.00 each).

 

[vroomzoomboom]

arrrg! if i would have seen this earlier, i think two of my parts trucks have good rockers!

 

[sport97]

What I did was cut all the old metal out leaving enough for the patch panel to lay over and still have some metal to be attached to. I used rivits to attach the repair panels. Bondo over it and paint. I used a bunch of tar/under coating on the back side so that it didnt get water in there. I also coated everything in POR-15(i used a different brand though).

 

[Dono]

I think I can handle this myself. Most of it is covered by a plastic rocker panel.
I wish there was a por15 type stuff in aresol I could just buy locally as I'd like to spray the inside really well before attaching the new dog legs.

Thanks for thinking of me on the parts, but Evil just might need them also at some point. Evil looks perfect! Congratulations. Its not an easy thing to do with the climate and salt we have on the roads.

 

[vroomzoomboom]

As said, I should have 2 sets that are basically rust free. Also, give either rondex or imperial body supply (they are on logan ave). They might have something you can use to spray the insides with. When I did evil, we used rocker guard thinned out, with a garbage spray gun and a nozzle. Used so much, it dripped for about 2 days lol.

 

[Curtis]

buy replacement panels or cut off a rust free explorer.
welding them on is preferred, but bonding/screwing/riveting will work.
And as you mention most is covered by the plastic covers.

My Dad did this a couple years ago, I posted pics of his work... he surprised himself!

http://www.explorerforum.com/forums/showthread.php?t=224548

 

[Dono]

Nice job Curtis!

So, I picked up my doglegs. They are not OEM style, but appear to cap over top of whats there.

What is the best thing to do? Should I cut the bad rust out, treat everything I can, and then just use that automotive body 2 part epoxy to glue in place (With a couple of screws to hold it tight till it cures)?

Then I can blend the seams with bondo?

 

[vroomzoomboom]

yep. cut all the rust out. if you can, treat the remaining metal with any rust inhibitor. grind away some paint so your bonding adhesive will stick (both on truck and patch panel). you can use screws or rivets to hold it in place until it dries. remove screws or rivet heads and mud her up! then when its sanded (start with 40 or 80 grit, end with 220), use high fill primer, sand that with some 320 then paint

 

[Curtis]

yep. cut all the rust out. if you can, treat the remaining metal with any rust inhibitor. grind away some paint so your bonding adhesive will stick (both on truck and patch panel). you can use screws or rivets to hold it in place until it dries. remove screws or rivet heads and mud her up! then when its sanded (start with 40 or 80 grit, end with 220), use high fill primer, sand that with some 320 then paint

 

[Dono]

Thanks Guys!
I'll start this weekend.

 

[Dono]

ok, turns out my panels weren't slip on. I had to grind the welds off and make a cut across the top. Minor setback though.

After epoxing the panels, and going for a shower my eye started to hurt. Next day, hospital as it wan't getting any better. They pulled a couple of small metal slivers out of my eye with a needle. Then the rust that was already starting needed to be scraped out off my eyeball. The experience sounds worse than it was.

mental note: Go get a set of full safety goggles (Not the safety glasses) for the next time I grind metal. OOps. Safety glasses are obviously not good enough.

I'm fine, in a few days it will be like nothing happened. Just posting my setback as I hoped to be bondoing today, and a reminder to all of you to be careful and use full eye protection.

 

[Curtis]

ok, turns out my panels weren't slip on. I had to grind the welds off and make a cut across the top. Minor setback though.

After epoxing the panels, and going for a shower my eye started to hurt. Next day, hospital as it wan't getting any better. They pulled a couple of small metal slivers out of my eye with a needle. Then the rust that was already starting needed to be scraped out off my eyeball. The experience sounds worse than it was.

mental note: Go get a set of full safety goggles (Not the safety glasses) for the next time I grind metal. OOps. Safety glasses are obviously not good enough.

I'm fine, in a few days it will be like nothing happened. Just posting my setback as I hoped to be bondoing today, and a reminder to all of you to be careful and use full eye protection.

Excellent! We'd love to see pix.

And our eyes are very important.. I always wear wrap around glasses.. I learned the hard way too, Had to have my eye lid flipped inside out to remove metal.. that was not fun, the worst 'surgery' Ive ever had

 

[Dono]

here's a couple of pics. Just waiting on me to bondo the one seam. I didn't take a picture after I had treated the rust, and painted the inner panel. Its not going to be perfect, but pretty close.

On the top of the dog leg, I overlapped the original metal and the metal of the dog leg (Dog leg underneath) so that I had a surface to epoxy to. Since I don't have a welder, Im going to bondo over the holes after roughing the area up. Not the right way, but I'm hoping it will last.

 

[sport97]

Looks great. As long as you go a good job painting and sealing it so water cannot get in it will be good as new.

 

[Dono]

its the sealing part that is an issue. Being that my exploder is a 'sport' there are plastic panels that cover the rocker panels. This is great, except there are holes in the rockers. This will let water and mud/sand in. Im not sure there is anything I can do to stop it.

I will coat the wheel wells, and anything that isnt going to be visible after the panels go on with undercoating after bono and painting.

 

[Joe Dirt]

Spray the inside with grease/oil before you put the plastic on.

 

[sport97]

its the sealing part that is an issue. Being that my exploder is a 'sport' there are plastic panels that cover the rocker panels. This is great, except there are holes in the rockers. This will let water and mud/sand in. Im not sure there is anything I can do to stop it.

I will coat the wheel wells, and anything that isnt going to be visible after the panels go on with undercoating after bono and painting.

I know what you mean about the holes. I have a new rocker on the driver's side and I haven't been able to bring myself to drill holes into my new rockers to remount the trim.

 

[Dono]

I almost want to drill a few drainage holes in the bottom of the rockers and dog legs. Then, of course, there will still be issues with the holes clogging with dirt.