rusty sill repair

[robmog]

i have severe rust issues in my rockers. my fix
the left side involved fender flange, b pillar and both inner and outer rockers.
picture 1: remove lead with propane torch revealing rust
2: fender flange rust
3: fender flange removed by drilling out spot welds

[robmog]

replacement flange from stoddard has updated mountings.
i salvaged the old "t" nuts, patched the square holes,attached the nuts, and mounted using the old outer rocker as a reference, plug welding in place

[robmog]

next the sill comes off using a cutoff saw to get to the inner rocker.
then grind off the spot welds of the door seal gutter and bottom outer rocker to remove remaining sheet metal.
the quarter is cut to get access to the "kidney" bowl. more rust!

[robmog]

kidney off, more rust!
jack point is shot too.
to remove jack tube you have to drill out the inner weld point shown
in picture 3

[robmog]

its amazing how much dirt can hide in the rocker!
inner rocker is bad, so off it comes by grinding the spot welds.
then a coat of eastwood's rust proofer.

[robmog]

new inner rocker plug welded on.
next i cut off the rusty inner bodywall behind the b pillar.
oops pictures are rotated

[robmog]

patch piece fitted, obtained from stoddard, longitudinal repair panel, $275, ouch, but it fits.
patch plug welded in.
welds ground smooth.

[robmog]

jack tube fitted and tacked in position.
don't forget to weld the inboard portion.
the plug weld the re-enforcement flange.

[Flieger]

excellent work and presentation

[robmog]

kidney bowl and outer rocker fitting requires re and unmounting the door many times but it pays to get it right.
once position is established, plug weld the kidney in place.
then plug weld the rocker
i tacked it front and rear then set the door gap by pushing up on the bottom.
a real PITA!