Ordered some rocker panel patches

[massacre]

My rockers are in bad shape, so i bought some rocker patch panels to fix them up. Otherwise i will not pass inspection. Once they come in, i'll see how well they fit and figure out the best way to weld them in

 

[RangerX]

Are they made for a gen1 or are they more generic? Have a link?

 

[wollimann]

Otherwise i will not pass inspection.

Thumbs up for this project!

Rocker Panel below door fits 1991-1994 Ford Explorer 4 door rust repair PAIR | eBay.de

Also molding holes will have to be drilled. 91-01 Ford Explorer 4 Door. We’re are also your number one stop for Stepvan / Walkin Van parts! Applications to Fit.

www.ebay.de

Experience shows that the inside panel and both doglegs rusted out too.

1991-2001 Ford Explorer 4 Door Dog Leg - Right Side | Mill Supply, Inc.

Happy grinding, welding and painting.

LD50 1st gen Rusty rocker panel bodywork - rockerpanel replacement

Hello fellow explorer enthusiasts! Got some questions asked while doing my driver`s side rocker panel repair so I decided to write-up the other side. Hope I can help anyone out.. FIRST: -Disconnect your battery, do not do any welding with your battery connected. Yes you might get away with...

www.explorerforum.com

 

[massacre]

Thumbs up for this project!

Rocker Panel below door fits 1991-1994 Ford Explorer 4 door rust repair PAIR | eBay.de

Also molding holes will have to be drilled. 91-01 Ford Explorer 4 Door. We’re are also your number one stop for Stepvan / Walkin Van parts! Applications to Fit.

www.ebay.de

Experience shows that the inside panel and both doglegs rusted out too.

1991-2001 Ford Explorer 4 Door Dog Leg - Right Side | Mill Supply, Inc.

Happy grinding, welding and painting.

LD50 1st gen Rusty rocker panel bodywork - rockerpanel replacement

Hello fellow explorer enthusiasts! Got some questions asked while doing my driver`s side rocker panel repair so I decided to write-up the other side. Hope I can help anyone out.. FIRST: -Disconnect your battery, do not do any welding with your battery connected. Yes you might get away with...

www.explorerforum.com

Looks like these are the ones i ordered.

 

[safehaven]

Interesting project.

 

[410Fortune]

Consider 3m panel bond instead of welding

 

[Mr Mumbles]

the best way to weld them in

TIG preferred. MIG ( with gas) next best way. No Flux-Core wire used for body work.

 

[massacre]

They came in, but i haven't taken them out of the box yet.
I have a water-cooled TIG machine, but i'll likely use my MIG welder, much faster. I have plenty of gas and a 30lb spool of wire.

 

[massacre]

Opened the box, these are pretty beefy pieces.

 

[massacre]

Consider 3m panel bond instead of welding

Interesting- never used panel bond before.
I'll look into it.
Do you have any advice?

 

[massacre]

No advice then?

 

[wollimann]

I would prefer welding but maybe bonding is an option

https://multimedia.3m.com/mws/media/1648170O/3m-panel-bonding-and-impact-resistant-structural-adhesives-rev-apr2019-pdf.pdf

 

[Mr Mumbles]

but maybe bonding is an option

With bonding you'll need the two part epoxy cartridge plus the single use mixing tubes for them. You will also need the special two chambered caulking gun to apply the epoxy. These items aren't cheap so unless you can borrow or rent the gun or plan on using the system again in the future, welding might be the most reasonable way to go, especially if you already have the needed tooling on hand.

 

[410Fortune]

Oh sorry! I just saw this

Basically when doing patch panels we all know bare metal and welds rust
The key is to prevent the rust
Once you do your prep work bare metal should be covered in weld through primer
Then you can weld and then coat with more primer.
As soon as metal is exposed to atmosphere it begins to rust. No way around this. Even e best patches are doomed

So in comes panel bond
Most newer car bodies are assembled with glue
It’s stronger
It doesn’t rust

I bought a pneumatic flange tool
It’s a simple tool that you use to bend the metal around your patch into a “ledge” or “overlap”
With careful planning and cutting you can now just glue the patch panels on after you remove all the old rust and use the flange tool to make an indent the patch can rest in
3m panel adhesive is good stuff

Rocker panels and quarter panels and cab corners are a perfect place to use the glue instead of weld, because they are so susceptible to the salt and road grime

With old trucks with a low blue hook value lol like a 4 door gen ii explorer, many dudes will just knock the rust off, treat what’s left, and simply rivet or panel bond glue the new patch right on top of the old rocker. Some bondo or seam sealer can be used to hide the “overlaps” and gaps..
it all depends on how deep you want to dive into your repair. I see oanel
Bond as a better alternative to welding… so the flange tool was a great investment

 

[massacre]

Awesome replies, very helpful! Thank you!
I have several types of weld-thru primer on hand, i may just weld them in, mostly since i have a lot more experience welding than i do panel bonding. Knowing me i'd end up gluing them on crooked or something lmao

 

[410Fortune]

The more tools in our arsenal the better!

 

[massacre]

The more tools in our arsenal the better!

You're not wrong