Rocker panels Replacement

[zzjonze]

Hi , I'm trying to replace the rocker panels on a 1987 Ford f150.
I have done the driver side already and it came out pretty good. I had to cut out most of the floor on the drivers side due to rust but the passenger side is not to bad on the floor. I have a doner cab I got the rockers out of.
What I would like to know is what is the correct procedure to cut out old and weld in new rockers. The lower front pillar is rusted through and I will need to cut just below the door mounting pillar.(where the hinge bolts).
I am just not sure where to cut the passenger side peice around pillar. Should I grind (or cut spot welds) lower bracket that cab mounts are bolted to or should I cut it and make my new rocker match at the pillar and cab mounting bracket

Any replies will be appreciated
ZZ

[Len]

I would drill out the spot welds using a Wivico Bit like the one below. You should center punch each spot weld then, using a variable speed drill, drill each weld using a slow rotation and a drop of oil on each spot.

http://autobodystore.net/Merchant2/graphics/00000001/WivicoSpotDrill.jpg
Wivico Link (http://autobodystore.net/Merchant2/merchant.mvc?Screen=PROD&Product_Code=WSWRB&Category_Code=CDB)

I would cut a couple inches below the hinge using an angle grinder like this one.

http://autobodystore.net/Merchant2/graphics/00000001/CP875.jpg
Angle Grinder Link (http://autobodystore.net/Merchant2/merchant.mvc?Screen=PROD&Product_Code=CP875W&Category_Code=CDB)

You also need a holder for the disk like this one.
http://autobodystore.net/Merchant2/graphics/00000001/tn3m7491.jpg (http://autobodystore.net/Merchant2/merchant.mvc?Screen=PROD&Product_Code=3m7491&Category_Code=CDB)
I would use cutoff disks, like the one below, in the angle grinder and I'd use the "backing strip method to help me weld the two pieces together.


http://autobodystore.net/Merchant2/graphics/00000001/TNNOR89030.jpg (http://autobodystore.net/Merchant2/merchant.mvc?Screen=PROD&Product_Code=CTOW&Category_Code=CDB)

[MO-Cummins]

As Len says those spot weld cutters work real well for drilling off your new panel. As for your old one another suggestion is to take the shown angle griner or something like it and put a grinding wheel on and grind the spot welds down then pop off your old one. It is just another suggestion for if your gonna weld your new panel on the you will still have a solid flange to weld to. Those spot weld bit can go right through both layers if your not carefull.

Here is a picture of how i would cut it out. If i am understanding the right panel here.

http://i6.photobucket.com/albums/y239/dezlsmkr/Clipboard02.jpg

[zzjonze]

yes that is where I was about to cut it. with die grinder and saws all.all that is spot welded to a brcaket underneath side and I was wondering if I should just cut bracket and weld part of the new one too.I think it may make it structurally stronger. But I didnt know if that was the way it is suppose to be done.
On the drivers side I cut out part of the underneath bracket and drilled spotwelds out of floor so I could get in to weld from the top side instead of upside down. Then I welded floor back over it.
Right now it is to hot to be out there so I will wait a day or two.
I will post some pictures of driverside in aminute. Thanks for the adivce all.
ZZ

[zzjonze]

Drivers side.
I have never done body work before but you guys made it sound easy, well wasnt easy but it is done.Have to thank Len because I got the idea from his door panel repair. But instead of welding the back and corner of the cab I bonded it with fusor.It made a real small seam that hopefull will never rust. I did weld the pillar inside the cab corner though.
The reason I posted my question is this took me about 2weeks studying and cutting and welding. and I was wondering if I was doing it right. Or an easier way
ZZ197

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[zzjonze]

worst words a body guy can say "oops I goofed" least it was on the pictures LOL!
ZZ
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