Rocker Panel Rust - Recommendations to Resolve

[FarFire70]

Another 'what do you think to fix this tumor' post - yup. Appreciate advice on getting after this as I have a lackluster track record on bodywork thus far and want to work to do better.

Here's the driver-side rocker in front of the rear tire:

Edge round from the opposite side:

Problem 1:

For the forward rust that is the OEM nutsert for the fender:

I was thinking at first to see how far the damage is by removing the paint and then cut out that cancer. If it wasn't too much larger than the circle, I thought to just paint & leave the cut area as it would be under the rocker guard.

Thoughts?

My concern (and lack of understanding bodywork in-depth): If I fill the cut out area with a panel - what do I do with the raw backside? I can't get in there to paint. Do I just leave it raw? — seems like that would just rust again.. [please excuse my ignorance - really want to try to learn body work, despite it being my least favorite car/Jeep DIY activity]

Problem #2

That rear corner is bad. I will certainly get it all back to real (non-cancer) metal.

I am putting on Fluxor aluminum corners and Rokmen rocker guards (unless I decide to give in and go Fluxor rocker guards.... {don't tell my wife I'm think about that yet} ).

So, I can do some really simple repair with a path but I don't think the armor will cover enough that a 'half-ass' self-made patch. (half-ass as I'm not at the still level for this complex feature...)

I think my best option is to get a manufactured patch panel for the corner (and even better if it includes the nutsert rust area) - But I haven't found a source for such a part.

Any recommendations for who makes replace rocker panel pieces?

Same question - what do I do about the raw backside?

—-

This has been in my mind for a long time since I removed the rockers so appreciate anyone who read this long post. More appreciate any helpful advice.

 

[lBasket]

If noone makes the parts maybe you could get cutouts from a partout

 

[FarFire70]

If noone makes the parts maybe you could get cutouts from a partout

Thanks! That's a good option I hadn't considered.

 

[macleanflood]

I think I'd treat the rusted areas with rust converter...find the rest of the rot you're not seeing (frame? torque boxes? fenders?)

Sounds like you plan on wheeling the Jeep...I'd be less concerned about cosmetics...but maybe keep your eyes peeled for a clean tub.

-Mac

 

[Rickyd]

If you have rust between panels you need to separate and media blast or sand it clean. Being careful you don't load the body up with sand.

I would get a replacement rocker skin and open it up. When I did paint and body i used weld thru zinc paint imbetween panels and inside rockers that is meant to be welded on. Depending on the situation, drilling access holes in the back so you can coat the inside of rockers is a good idea. Make the holes a size you can get snug fitting rubber plugs for.

Or you could just use a hammer and drift to knock as much rust out of the area as possible and rust convert it with your favorite por15 type stuff and bury it in coatings.

At least it isn't as bad as this tj-
https://wranglertjforum.com/threads/best-options-for-rust-repair-on-tub.75990/

 

[TheBoogieman]

Another 'what do you think to fix this tumor' post - yup.

 

[FarFire70]

I think I'd treat the rusted areas with rust converter...find the rest of the rot you're not seeing (frame? torque boxes? fenders?)

Sounds like you plan on wheeling the Jeep...I'd be less concerned about cosmetics...but maybe keep your eyes peeled for a clean tub.

-Mac

I certainly plan to off-road but also want to be able to DD it when the weather's nice so I'd like to keep the cosmetics somewhat - ack that there's line to be drawn on how much work I want to do on cosmetics the further I get into more black trails.

I'm really hoping I can repair vice tub replace.

find the rest of the rot you're not seeing (frame? torque boxes? fenders?)

If you have rust between panels you need to separate and media blast or sand it clean. Being careful you don't load the body up with sand.

I would get a replacement rocker skin and open it up.

I agree - this is what worries me the most - what I can't see. I plan to try to find some time this weekend between other house chores to bust out the auto body tools to at least cut back to health metal to see how bad things are beyond the surface.

When I did paint and body i used weld thru zinc paint imbetween panels and inside rockers that is meant to be welded on. Depending on the situation, drilling access holes in the back so you can coat the inside of rockers is a good idea. Make the holes a size you can get snug fitting rubber plugs for.

Thanks!

As I was watching some videos this seems to be a good way to go - use weld thru zinc primer on the back (buried) side but then come back through some accessible holes with cavity wax for a final coat inside.

Or you could just use a hammer and drift to knock as much rust out of the area as possible and rust convert it with your favorite por15 type stuff and bury it in coatings.

At least it isn't as bad as this tj-
https://wranglertjforum.com/threads/best-options-for-rust-repair-on-tub.75990/

I saw that thread as I searched the forum. Sad the OP didn't stick around to share more bodywork tips.

 

[FarFire70]

After researching into anyone I could find that sells replacement Jeep panels, I found these from Classic Enterprise:

https://www.classicent.com/products/jeep-lower-side-repair-strip-1951-1987

We used CE at a Jeep repair shop I worked at in the early 2000s and they were good quality then. I couldn't recall the company name until I dug deep (I actually used Grok from X to help dig up companies).

I reached out to Mark there and he confirmed this would meet my needs without going up to the 'Jeep' embossed part of the tub and/or getting the full rear corner - which would be a savings of $100+. That's assuming the Problem #2 above doesn't go too far north...

I really need to get this opened up this weekend.