Now this is rocker rust!

[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!!

[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.autonationfordwhitebea...lar-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/...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...t-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. )