2nd Gen Non-Engine/Transmission Anyone interested in my no-weld rocker panel repair???

[mwilson]

The rocker panels were getting bad on the '97, time to deal with it.



I have cut the rotten area out and am preparing the cab for the repair. I don't want to weld them on so I talked to my body shop regarding alternative methods. I sell the adhesive that holds the 3 part Freightliner Truck hoods together so I asked if such a product exists for metal to metal repairs.



Well it does exist and is called "Fusor". Made by Lord chemicals. Can be used by itself for non-structure repairs. It is available in a common caulking gun size tube so a DIY can use it without buying the big, double plunger commercial applicator.



If any are interested I will photo and post the results, be they good or be they bad... .....





If it goes as planned -laf) I will paint the rocker panels ahead of time and simply glue them on. The "Fusor" will also seal the edges. Quite an idea at the least.



Let me know...



Mike.

 

[HPSimpson]

Mike,
Yes I would like some information and of course picture. Sounds like a method that I will need to do shortly, thanks!

 

[Axtell3]

I'd also be interested, living about 30 miles from a salt mine.

 

[Bob4x4]

That along with resistance welding is how many cars are being built theses days

 

[Bill Lins]

I'd also like to hear how it works out, Mike.

 

[moparguy]

3M panel bond is great. The 3M product is a bit more $ and takes a special gun (that I borrowed from the paint store) but came highly recommended. I used it to bond a body kit to the V8 Miata 2 years ago, no problems. I also used it to replace a damaged body panel,,,, no issues structurally, but as the pros warned, after 2 years I can see a ghost line where the panels meet. If you're the least bit anal about paint, do some research on the last item.

 

[mwilson]

3M panel bond is great. The 3M product is a bit more $ and takes a special gun (that I borrowed from the paint store) but came highly recommended. I used it to bond a body kit to the V8 Miata 2 years ago, no problems. I also used it to replace a damaged body panel,,,, no issues structurally, but as the pros warned, after 2 years I can see a ghost line where the panels meet. If you're the least bit anal about paint, do some research on the last item.

The '97 is on borrowed time after a lifetime in the Northeast. I think that a rocker panel is down low enough to not catch one's eye like a body panel would.



I do think that if I trim the replacement rockers properly it should not be too bad.



Mike.

 

[S.Morris]

Can't see any ghost lines under stone guard

 

[mwilson]

Well, after a hundred other things got taken care of I am finally back to the '97.



Losing 1/2 of my summer due to the shoulder injury has put me behind the ol' 8 ball.....



I hope to glue the panels on tomorrow, the weather has been very wet and I really need things to dry out before I do it.



These shots are taken right after I got the old rockers cut off, I have done a lot more cleaning and prep. I will get some more pictures on here as time permits.



We also removed the coffee stained, smelly old carpet and attacked it with the pressure washer and greased lightning. The wife did a great job getting it clean. It's not perfect but is a 100% improvement. She has always complained of the smell and does drive the truck quite a bit as she is not comfortable at all driving the Mega.

 

[mwilson]

Rocker panels trimmed and painted just waiting... ... .

 

[rrl989]

Wow, can't wait to see the finished job ! Where did you get the replacement rock panels from ?

 

[mwilson]

Wow, can't wait to see the finished job ! Where did you get the replacement rock panels from ?

I got them from Quirk Auto Parts. Keystone / LKQ offer them as well.



There are two choices, one being a complete rocker panel and the other called a "slip-on" which is what I bought. There is still a left and a right panel even in the slip-on style.

 

[GHarman]

Excellent thinking, there, mwilson!
GregH

 

[Axtell3]

My rot box is quivering with excitement. What are you going to clamp with?

 

[mwilson]

My rot box is quivering with excitement. What are you going to clamp with?

Sheet metal screws up top where the weatherstrip goes, remove after it dries. Down bottom I will use several sets of vice grips.



That's the master plan at this point (subject to change as the situation deteriorates).



Mike.

 

[Axtell3]

We are all the same. sounds like it'll work.

 

[mwilson]

Only have a minute but wanted to update... . RH rocker is on and the adhesive is drying sloooooooow. The weather is frustrating me this summer for sure.





A little background here, my uncle was a bodyman and drank himself to death. I believe that I know why... ... .....



I HATE bodywork... .

Mike.

 

[DavidC]

Wow, quite the curb finder collection you have going there. All kidding aside it looks good.

Dave

 

[HHhuntitall]

Mike,

When I worked for an industrial contractor, we had a big job with a certain Red Oval truck manufacturer nearby... . They used some green stuff made by LORD, IIRC. But I also remember seeing some stuff called Fusor... .

Anyway, I had to work on one of the low voltage control boxes on cab assembly, where there are robot arms for setting cabs... . They dropped a tube of this stuff in the under-walk, where all my wires ran, and I stepped on it in the dark... . It blew out and I walked through it several hours working, until I finally started noticing my boots didn't want to move if I stood in one spot too long..... Then I played with it a bit, and got some nice balls rolled up, probably around 3-4" in diameter. It was a dark green, though. Once that crap hardened, it was like one of those high-energy balls the kids buy at the restraunts... . You know, you drop it 3 feet and it goes 10 feet in the air... So I got in the habit of putting them (I had #1 and #2) above doors so it'd fall out when they rolled the door down, or throwing it from the rafters in the warehouse..... I screwed with those two balls for 6 months or better!! I'd lose them a day or two, and then someone would find one and bring it back to me... . I'd keep it in my tool belt until an opportune moment arose... . One even escaped the warehouse once, bouncing off down the driveway towards the hitch and dyno test facility..... It wound up in the office (we had a portable building for our office on site) a few days later with a note... ... "Please dispose of this in the office area. " Okay. They both escaped there after a few days and ended back in our office. Not sure how it got out of the women's restroom, but whatever.....

They were sure tough! They got drove over, hit with hammers, dropped in the assembly line drives, thrown down from 40-60' in the air onto concrete, doused in oil and paint and cleaner... ... We even doused it in brake parts cleaner and batted it across axle trim with a piece of pipe one time..... dang that crap was tough!!! Brake parts cleaner turned the edges white and kinda chalky... could've been the fact it was on fire, too... .

Supposedly, there were some smaller ones made the size of golf balls, and corporate had fun with them in the office, but that must have been after I left.....

 

[Joe Mc]

I like it! Beats the hell out of the old weld - grind route and you paint them "before" installation!!!! Awesome. Can't wait to see more. Where'd you buy the stuff anyway, sorry if you already told us, but would like to get some.