Rust control on rockers

[nitro71]

I have a patch of rust I'm going to grind out. It's about 8-10" long and still in the rocker. Expecting a 8-10" X 1-2" hole. What should I paint and fill it with?

The other holes in the rockers have me concerned about new rust getting a grip. Is there anything I can coat or pump into the rocker holes to prevent it? Seems like a very poor design decision by Ford..

I was thinking of repainting my rockers as either side of the vehicle has a different color. One is greyish, the other is black.

 

[Dennis1188]

Here are some links for you:

 

[Dennis1188]

Try this again...

http://www.explorerforum.com/forums/showthread.php?t=171419

http://www.explorerforum.com/forums/showthread.php?t=227645

http://www.explorerforum.com/forums/showthread.php?p=1875919

http://www.explorerforum.com/forums/showthread.php?t=120559

 

[nitro71]

Since I don't know how to weld.. I'm going to grind it out. Spray it with spray paint and put the trim panels back on. Might pump some paint into the rockers.

 

[Joe Dirt]

http://www.por15.com/

 

[Curtis]

Here's what my dad had to do with his... much worse than what yours is Im sure

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

 

[nitro71]

I'm gonna fire the grinder up today and get the rust out. Mines not bad. I just need to stop it from spreading.

 

[Curtis]

I'm gonna fire the grinder up today and get the rust out. Mines not bad. I just need to stop it from spreading.

9 times out of 10 you're gonna end up with a much hole bigger than you thought. Been there... done that.

The rockers on these rust from the inside out

Ideally you will need a patch panel. Autozone or Advance will sell small pieces of sheet metal. If you don't have a welder you could make a lip on the truck so a new piece will sit flush when against it and pop rivet it on, and then some body filler.

If the hole has any size at all you wont be able to fill it without a patch panel.

Before you cover the hole, get some good primer sprayed inside and on the back of your patch panel.

After and only after you paint, drill a couple small holes into the rocker panel where you can spray a rust preventative. Something oily like WD40 but wont evaporate. Not sure whats available here in the US but in Canada there is a product called "Rust Checks".
I think here in the US you might find "Fluid Film" or "ziebart"

If you spray that stuff before you paint, it will run into your wet paint