Attention: TDR Forum Junkies 
I Purchased a 2003 Dodge 2500HD Quad Cab short box Cummins just over 2 years ago. I'd like to share a couple of the projects I've done to the truck.
The first major project (November 2013) was to eliminate the rocker and cab corner rust. In investigating the panels it became clear that a simple rocker panel replacement was not going to cut it. Coming from an offroad background with Jeeps and sand cars, my thoughts turned to rock sliders. Rock sliders are basically round or square tubing that is fastened or welded on / into the rocker of a vehicle. I had already done a set of rocksliders on a previous vehicle and after some measurements I pulled the trigger.
I ordered some 3" x 3" x 0.125" square tubing pre-cut to 84" from online metals. I also used some sheet metal I had laying around.
As you can see from the pictures, the truck was pretty rough. The rocker is made up of three different sections of sheet metal. The inner, the middle and the outer. The inner - I left pretty long and used it as a back stop for the 3x3 tubing. The middle, which I cut at the oval sections, determined the vertical position of the square tubing. The outer piece I cut up pretty high in order to thoroughly weld the middle section to the top of the tubing. I then added sheet metal to bridge the outer back down to the tubing.
Once the tubing was in place and the sheet metal welded, I de-badged the entire truck,(remaining badges removed just after photos) sanded everything down and used Monstaliner to coat the new rockers. I also added Monstaliner around the truck to prevent further rust. (GREAT product by the way)
It was quite a hero effort, as I pulled it off in 1 weekend by myself. I had to get it painted before winter hit and it was the last work weekend predicted.
The first major project (November 2013) was to eliminate the rocker and cab corner rust. In investigating the panels it became clear that a simple rocker panel replacement was not going to cut it. Coming from an offroad background with Jeeps and sand cars, my thoughts turned to rock sliders. Rock sliders are basically round or square tubing that is fastened or welded on / into the rocker of a vehicle. I had already done a set of rocksliders on a previous vehicle and after some measurements I pulled the trigger.
I ordered some 3" x 3" x 0.125" square tubing pre-cut to 84" from online metals. I also used some sheet metal I had laying around.
As you can see from the pictures, the truck was pretty rough. The rocker is made up of three different sections of sheet metal. The inner, the middle and the outer. The inner - I left pretty long and used it as a back stop for the 3x3 tubing. The middle, which I cut at the oval sections, determined the vertical position of the square tubing. The outer piece I cut up pretty high in order to thoroughly weld the middle section to the top of the tubing. I then added sheet metal to bridge the outer back down to the tubing.
Once the tubing was in place and the sheet metal welded, I de-badged the entire truck,(remaining badges removed just after photos) sanded everything down and used Monstaliner to coat the new rockers. I also added Monstaliner around the truck to prevent further rust. (GREAT product by the way)
It was quite a hero effort, as I pulled it off in 1 weekend by myself. I had to get it painted before winter hit and it was the last work weekend predicted.
