Now this is rocker rust!

[Agent2006]

....rumbling down the mean streets of Philly...here's what you get! underneath the black plastic rocker trim panel. Drivers side 100x worse than the pass side...only a small breakthrough there.

Actually interesting...either rusted through or solid as the day it left the factory. Leads me to think the low spots where the salt water sat = rusted spots.

The plan is to cut out the rusted areas and 3M panel bond adhesive-in the new rocker panel pieces in an overlap style, then rhino liner everything, or rustoleum or spray bed liner on the back side...I'll update when the patch panel gets here.

Rock Auto only has them to 1997 ($20 bucks) , it'll work fine, must some side-impact thing why they don't want to sell newer years.The gauge and shape is the same.

[Invective]

....rumbling down the mean streets of Philly...here's what you get! underneath the black plastic rocker trim panel. Drivers side 100x worse than the pass side...only a small breakthrough there.

Actually interesting...either rusted through or solid as the day it left the factory. Leads me to think the low spots where the salt water sat = rusted spots.

The plan is to cut out the rusted areas and 3M panel bond adhesive-in the new rocker panel pieces in an overlap style, then rhino liner everything, or rustoleum or spray bed liner on the back side...I'll update when the patch panel gets here.

Rock Auto only has them to 1997 ($20 bucks) , it'll work fine, must some side-impact thing why they don't want to sell newer years.The gauge and shape is the same.

http://cdn1.sbnation.com/imported_assets/1606881/WhatHasBeenSeenCannotBeUnseen-1.jpg

Looking forward to seeing the repair.

[Maverick pro]

....rumbling down the mean streets of Philly...here's what you get! underneath the black plastic rocker trim panel. Drivers side 100x worse than the pass side...only a small breakthrough there.

Actually interesting...either rusted through or solid as the day it left the factory. Leads me to think the low spots where the salt water sat = rusted spots.

The plan is to cut out the rusted areas and 3M panel bond adhesive-in the new rocker panel pieces in an overlap style, then rhino liner everything, or rustoleum or spray bed liner on the back side...I'll update when the patch panel gets here.

Rock Auto only has them to 1997 ($20 bucks) , it'll work fine, must some side-impact thing why they don't want to sell newer years.The gauge and shape is the same.

Fluid film the inside of the rockers after you do your repairs.
Then fluid film the entire underside of the car. Dont forget inside your doors also.

[offroadkarter]

holy ****, I had a feeling this would have some holes after it was actively shucking rust and crunching when we were jacking it up, but wow.

grab the POR15

[SteelQualityMan]

Fluid film the inside of the rockers after you do your repairs.

Then fluid film the entire underside of the car. Dont forget inside your doors also.What is "fluid film" ?

Sent from my SM-N950U using Tapatalk

[offroadkarter]

What is "fluid film" ?

Sent from my SM-N950U using Tapatalk

it's a rust prohibiting spray that was developed in the 40's to keep tanks from rusting in WWII

https://www.fluid-film.com/

[crownvic97]

Meh, that’s not so bad!

[Maverick pro]

Most people just undercoat there vehicles but that alone will not work. Once undercoat gets a rock chip rust starts again and is hidden by the undercoat. Fluid film actually fills in any paint chipping that happens cause it's a thick lanolin based oil that doesn't wash off easy. Only down side to it is it makes a mess trying to work on your vehicle after it's applied. But I would rather have dirty hands than rust build up anyday. It also has a farm smell to it for a day or so. It's also amazing for any rubber parts on your suspension.

[Shinker]

My 03 has quite a bit of rust in the rocker panels too. After I replace the rusted areas I was gonna use por15 and was thinking about trying some 3M cavity wax inside rocker. 3M sells a long tube that attaches to their cavity wax aerosol that would be nice to get inside the frame too.

[Agent2006]

The question is --did these rust outside in... due to salt/ice between the plastic trim cover and the rocker, or from the inside/out? Makes a difference as to the prevention strategy...I'll let you guys know when I start slicing mine open. Misapplied rust or wax treatment might hold water and create MORE problems. Maybe these rockers need drain holes instead. all I know is mine has the drain holes now...LOL

[Shinker]

The question is --did these rust outside in... due to salt/ice between the plastic trim cover and the rocker, or from the inside/out? Makes a difference as to the prevention strategy...I'll let you guys know when I start slicing mine open. Misapplied rust or wax treatment might hold water and create MORE problems. Maybe these rockers need drain holes instead. all I know is mine has the drain holes now...LOL

I also wondered if the rust in the drivers side rocker could be caused from moisture getting under the plastic sill cover. I have seen people hit that area with pressure washers. On my 03 I found a missing rubber plug on the inside of the rocker panel and found telltale signs of mice inside the rocker. They also got into the frame on the right front. Was a pain to clean that out. Previous owner had given up fixing the engine and stored it outside for a couple years. I want to tackle my rocker rust too but waiting till I set body back down. Had visions of car sagging as I drilled out the spot welds. Watching your progress with interest.

[Maverick pro]

My 03 has quite a bit of rust in the rocker panels too. After I replace the rusted areas I was gonna use por15 and was thinking about trying some 3M cavity wax inside rocker. 3M sells a long tube that attaches to their cavity wax aerosol that would be nice to get inside the frame too.

We use the 3m wax at work good stuff. The long applicator works awesome.

[Maverick pro]

The question is --did these rust outside in... due to salt/ice between the plastic trim cover and the rocker, or from the inside/out? Makes a difference as to the prevention strategy...I'll let you guys know when I start slicing mine open. Misapplied rust or wax treatment might hold water and create MORE problems. Maybe these rockers need drain holes instead. all I know is mine has the drain holes now...LOL

Wax or fluid film does not hold water. It actually repels the water from sticking and pooling up. It also does not allow salt to stick to whatever is sprayed. The rockers do have drains but they are so small along the pinch welds they plug up easy. Adding larger holes like you mentioned is not a bad Idea.

[Maverick pro]

The question is --did these rust outside in... due to salt/ice between the plastic trim cover and the rocker, or from the inside/out? Makes a difference as to the prevention strategy...I'll let you guys know when I start slicing mine open. Misapplied rust or wax treatment might hold water and create MORE problems. Maybe these rockers need drain holes instead. all I know is mine has the drain holes now...LOL

Looking at your pictures it seems they rusted from the inside out.

[01BADMERC]

Wax or fluid film does not hold water. It actually repels the water from sticking and pooling up. It also does not allow salt to stick to whatever is sprayed. The rockers do have drains but they are so small along the pinch welds they plug up easy. Adding larger holes like you mentioned is not a bad Idea.Exactly why I don't undercoat my vehicles. Plugs up the factory drain holes being small enough already.

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[Grimrepairman]

I feel your pain.
This is the main reason I got my excursion cheap. Came with the new rockers in a box. Now, if I could figure out where to get the corner piece I might actually do them.

[Agent2006]

Grimrepairman...either get some rust free ones cut out of a wreck or see if F150 corners might fit?

[MyBlackBeasts]

I feel your pain.
This is the main reason I got my excursion cheap. Came with the new rockers in a box. Now, if I could figure out where to get the corner piece I might actually do them.


http://www.cooltruckparts.com/


Go git 'em!

[Grimrepairman]

Thanks MBB, but I nothing comes up on the website for excursion. I might be doing something wrong.
Agent2006, I believe cab corners from a crew cab f2/350 will be close for part of it.
In dream land I find a nice clean 7.3 one and move on with my life.

[Agent2006]

OK:

1997 Grand Marquis left rocker replacement panel (can't get a 2003 panel) from Rock Auto was 20 bucks...is about 22 gauge steel. front patch fit OK --rear patch needed some trimming (wasn't wide enough had to go cut up the side of the patch panel rocker a bit and hammer it flat, trim the bottom vertical section (too thick) then it worked. Overall - this is a tough job, but needed to be done. Showers of sparks, grit, hella loud, stinks like burning metal, all while laying on the cold garage floor.

1.cut out the rust on the drivers outer rocker, underneath the black plastic trim panel (HF grinder and 4 inch discs. I went through 4 discs)
2.Ground the paint down on patch panel and rocker
3.Got out the 3M panel bond
4.Test fit sheet metal screws and clamps
5.took it apart and applied the panel bond and clamps/screws again
6.4 hr work time at 73F I'll let it sit overnight
7.Tomorrow remove clamps and paint it. Screws can stay. They are on there for clamping the adhesive while it sets.
8.reinstall rocker trim

No more rust on that side!

[Marauderjack]

I feel your pain.
This is the main reason I got my excursion cheap. Came with the new rockers in a box. Now, if I could figure out where to get the corner piece I might actually do them.

That's HORRIBLE.....WOW!!:eek:

[crownvic97]

Looking good, certainly better than gaping holes!

[Agent2006]

It's ugly but 100% solid. Should last me until I win Powerball then I'm getting this thing 24K gold plated and a trilogy kit installed....

[offroadkarter]

OK:

1997 Grand Marquis left rocker replacement panel (can't get a 2003 panel)

You can still get the entire rocker from Ford, this is probably the route I'll go if I care to fix my 03

https://parts.autonationfordwhitebearl ake.com/v-2003-mercury-marauder--base--4-6l-v8-gas/body--center-pillar-and-rocker

[Agent2006]

Hey Offroadkarter:

That's the middle panel you linked that goes underneath the front doors only, has a fiberglass square tube attached. For extra strength during door slamming ,etc.. Its way too short to be the full length outer. Believe me, I checked around.

https://www.crownvic.net/ubbthreads/ubbthreads.php?ubb=showflat&Number=2768619

Now this guy up in CANADA has some rocker panel rust! Makes me feel better about my rockers

https://oppositelock.kinja.com/crown-vic-rust-repair-part-1-1705667917


Other option is: to get one cut from a wrecked taxi/cop car. Which will likely not be rust-free either...if it came from around here. Maybe a guy drove up from Arizona, was in Philly for only ten mins in the summer and got rear ended at a light...that'd be a good rocker.

I painted the patch panels with black rustoleum and back on! went the plastic rocker cover. The patches are ON THERE!...3M rocks. No more rust flakes falling off when jacking up the car. Actually where it isn't rusted this car is pretty solid. After I fix the much smaller pass side rocker hole, I might grind off the axle housing rust, and rear sway bar and paint that, then swap out all four springs.

Panel bond adhesive has got to be pretty good when Airbus uses panel bond adhesive to affix the tail on their jets. I know some prefer cut to fit, butt welded patches, but this is no Tucker 48 or a Duesenberg. The other thought is the variance between strong and weak with properly prepped panel bond pieces is much less than the difference between a MIG weld that is good, and a MIG weld that looks good but is weak. Hard to tell by eyeballing it, especially if you are a novice welder (like me. )