Advice on rocker replacement

[karmann57]

I was trying to get a little more work done on the Kombi yesterday and found something that has me questioning my direction in regards to the body repair.

This is what I found when I cut out a rusty patch behind the drivers seat...

This is what I cut out...

As you can imagine the rocker is pretty much gone on that side.

Here's my question. At this point shelling out another couple hundred bucks for replacement metal doesn't seem like a big deal (why not, the budget is gone anyway), so how hard do you think it would be to do the rockers? I don't doubt that I can do it, I'm more worried about how much time it's going to take. Anything in particular I should look out for?

Your wisdom as always is appreciated!


Shane

[dpeters81westy]

Chris is probably most qualified to answer this since he fabricated the sections for his DC project.

Maybe a browse through his pics on www.commercial-air.com
and see of they give you any insight.

- Doug

[karmann57]

Thanks for that Doug, the pictures did help.

I know Chris makes things look easy, but it may not be that bad. I'll just have to make sure everything the rocker attaches to is still in good shape or I may just be digging myself a bigger hole!

Luckily the passenger side rocker and all the sliding door bits are in good shape, I'm sure that would be a nightmare compared to the drivers side.

One last question, I'm looking at the replacement panel diagram and seeing the Inner Fender Splash Panel, problem is I can't quite picture where this is supposed to go. What I'm really worried about is if it's related to the area I will be repairing. Anyone?


Shane

[commercialair]

Oh Boy. How do I explain how it goes together. It's been awhile since I did that section. Here's the direct link to the pics:

www.commercial-air.com/images/68%20Double%20Cab%20Metal%20Work%20Gallery/index7.html

Basically, there is the inner rocker, intermediate, and outer rocker. They all come together at that point. If you look at the inner fender, directly behind the front tire, you can see the splash panel that you are talking about. That is the close-out for the whole works. It's the place that gets pelted by rocks, dirt and water as you drive and it takes a real beating. Once that area is rusted through it just carries down the rocker.

Once you start cutting you can see how they join. Your best bet is to remove the outer rocker and cut out the splash panel. With those pieces gone, and the floor section that you've already removed, you should have a clear view.

I'll try to find some more pics and e-mail them to you. I also have some inner rocker sections that I fabbed and maybe a few other pieces that you'll need.

It's not too complicated, but it will be time consuming (what isn't with these old buses??) Take lots of pics and I'll help out with anything I can.

Chris

[karmann57]

Thanks Chris!

I see listed on CIP1.ca the rocker panel and inner rocker, but no mention of the intermediate section, is this something I'd have to fab?

Good thing I'm going into Concept-1 soon anyway (Ken must love seeing me walk through the door, everytime I go in to pick something up I have another order for him!)


Shane

[commercialair]

This should help:

www.specialpatrolgroup.co.uk/spooky/sills/os/os.html



Chris

[karmann57]

That's perfect!

Thanks again for your help. Looks like I may have to fab that inner section, it doesn't look like the new panels come with.


Shane

[commercialair]

Glad that helps. If I remember correctly, the intermediate is thicker gauge than the inner and outer....16 or 18?? 5/8"X 5"

You can make it taller than it needs to be and trim the bottom after the outer rocker is welded on. This will give you more to clamp to as you go.

Also, use a straight edge from front to back as you clamp on the outer. The repro panels are usually pretty tweaked and they won't line up straight. A straight bottom line is important for the final panel to look right.


Chris