Reply to "2548's Restoration"

This area was badly rusted out, and after taking it apart, it is easy to see why. I’ve cut away the top part of the outer rocker here (what was left of it). It used to extend all the way back to the B pillar, where just a notch was cut out of it, and it continued rearward. The door striker cosmetic panel was curved down and forward, lapped over, and welded to the rocker / door sill about where my cut line is in these photos. This formed a wedge shaped little cavity just perfect for trapping all sorts of dirt, trash and water in there.



The masking tape helps me rough out the shape of the patch needed:





Here is the rough cut:



After some trimming and contouring:



I decided to use backer strips on this one, so I do not have to get it so perfect:



Test fitting looks good so far:



Clamping it in place to be sure it fits up right:



Next I have to make up pieces to patch the quarter panel and the top flange of the outer rocker:



The bottom of the outer rocker piece had some rust through holes too, so I made a patch for it:



Here I am just test fitting the repaired piece:



And the other repair pieces are taking shape:





More test fitting:



I flanged the top of this piece:



This little piece is needed to fill in a gap:



One last test fit with all the pieces in place:



Now to start welding:







One of the challenging questions is which piece to do last. It is easy to paint yourself into a corner, so to speak:



I do not have a pic of the repair after clean up. I’ll try to remember to take one. It looks better than this.

Tune in again for my next episode; the infamous rear wheel house repairs!