I'm goin' in deep! Lol

[Spinnakerblue89]

Has anyone here had any experience replacing the INNER rocker panels? Mine are completely rotted out and I purchased a set from BSP along with outer rockers. 

 

What's the best way to go about this? I don't want to just get to hacking it out without checking in on here. Attached is a photo of what it looks like on the interior. Thanks.

 

 

[pizzaman09]

Having done work like this, get some high quality thin cut off wheels for your angle grinder, I prefer DeWalt brand.  Then just start removing material from either the truck for the replacement panel until it fits how you want.  Decide if you are overlapping or butt welding it together.

[Spinnakerblue89]

I pretty much figure it'll be bit by but until I have the configuration that I want. 

[Pete M]

is the new piece attached via spot welds?  is it the exact same as the bad piece?

[Spinnakerblue89]

It certainly seems like it could be. I have to get more cutting wheels, I'm down to my last one. (I've been repairing an old Ranger simultaneous to this truck). 

[Pete M]

if it's a direct replacement, try and find the page from the shop manual that shows the spot welds and get to drilling.  

[Spinnakerblue89]

On 8/25/2024 at 10:01 PM, Pete M said:

if it's a direct replacement, try and find the page from the shop manual that shows the spot welds and get to drilling.  

Ah! But first I need to find me a shop manual.

 

I do have spot weld drill bits. I knew better than to pass up on those when I bought this.

[Eagle_SX4]

8 minutes ago, Spinnakerblue89 said:

Ah! But first I need to find me a shop manual.

You can get a reprint of the M.R. 278 body manual on rockauto for $20.79. https://www.rockauto.com/en/moreinfo.php?pk=13655417&cc=1181584&pt=10335&jsn=974

 

Lots of useful information in there.

[Spinnakerblue89]

Will all of this information apply to my '89? Or should I spring for the $79 four volume '89 manual?

[Eagle_SX4]

As far as I know the body did not change much over the years. Just the drivetrain. If the 89 manual is anything like the 86-88 manual then it won't have any info on body repair just how to take things off. (fenders, doors, and bumpers)

[Eagle_SX4]

I should clarify the 86-88 body manual shows the proper procedures for replacing welded body panels. The 86-88 shop manual refences mostly drivetrain and interior.

[Spinnakerblue89]

Damn man, I appreciate the tidbits. I'll be sure to order the book.

 

Hey on a related note, while I'm at it... Cab forward from the door, just before the wheel arch, the rust and rot continue on the bottom. This extends beyond the reaches of both inner and outer rockers. Is that going to be a case of DIY body repair or can those be replaced also? I don't recall seeing anything but rear panels for the truck bed.

[Pete M]

you're going to need a patch from an XJ if it goes forward of the replacement parts.   at some point you might be better off buying used rockers from a clean truck and seeing if they can cut more for the front bit.

[Spinnakerblue89]

41 minutes ago, Pete M said:

you're going to need a patch from an XJ if it goes forward of the replacement parts.   at some point you might be better off buying used rockers from a clean truck and seeing if they can cut more for the front bit.

I figured a Cherokee may need to suffice.