Rocker Replacement Part 2

So it's been quite a while since my last post and a lot has happen. For the most part the passenger side rocker panel is complete. I still have some finish grinding and a couple small floor holes to weld up.

When I left off in part 1, I had just finished removing the rocker panel. The metal underneath had some serious surface rust. I grinded away the surface rust and painted it with POR15.

Next I made my first there-is-no-going-back cut. I cut off the rusted A-pillar just above the lower door hinge bolt holes. I then cut out the inner kick panel. In the photo below you can also see where I welded in my first floor patch.


With the floor patch in place, I then welded in the new kick panel. It was a bitch getting it to align with the bottom shape of the floor. Mainly due to the shape of the floor patch. I ended up removing the first floor patch and redoing it a couple times before I was satisfied with the work. Sorry I don't have photos of the kick panel prior to installing the A-pillar. I then took the replacement a-pillar, bolted it in place, scribed a cut line, then cut it to fit and welded it in place. As you can see there is a big improvement of the rusted out piece.


Next I mounted the new rocker panel using sheet metal screws. Then one-by-one, I removed each screw and plug welded the hole. When I was done I grinded down the welds.