Rocker Panel Rusting on wheel side (wheel arch rusted it open) What to do?

7

777funk

I've noticed that one end of the rocker panel on the van I'm working on is open (due to the lower wheel arch being rusted through and letting water into the rocker). So, since only one side of the rocker is rusted, do I need to replace it? I'm planning to cut the wheel arch and weld in some new panels around the wheel.

But I feel bad about the rocker since I know it's seen road dirt and water. I'd hate to fix this thing and have it end up rusting through.

Anything I can do? It's still in good condition (except right next to the wheel where it's opened up from rust).
 
Cut it open and take a look inside, you can weld in new metal but the only way to stop it from happening again is to fix the factory design flaw that caused the corrosion to start.
 
I'm sure the inside at least has a thin layer of rust since I'm sure water has been inside. I've thought about cutting the major stuff out and trying to shoot cosmoline into the rocker but I don't know. Seems like rust is a no win.
 
Post up some pictures of what you're seeing and I'm sure we can offer up our best opinion on proceedure. You can win the rust fight if you do things right.
 
Finally got the camera and the van together on the same day and able to get a picture snapped.

Assuming there IS rust all over the surface of the inside of the rocker, what should I be doing? DSC_0002.jpg
 
That section of quarter is going to have to be removed and replaced, once it's off the rocker you'll be able to see how bad the corrosion is in that area. Are there any other areas along the length of the rocker that show corrosion coming from the inside?
 
I've done a few of these in the past. My bet is the more you open the more rust you are going to find. Did a Buick that had a hole the size of a quarter. Ended up replacing most of the rocker. Rust repair is so much fun... I would cut the section out that goes up to the seam and see how bad the rest is.
 
This is where I call the owner and run it by him. I lay out the correct way to approach the repair and caution that the deeper we dig the more way may find.
When these issues show up everything from there out related to the repair is time and materials.
 
The reason I said what I did is virtually all people with a vehicle like that can't justify the expense to do the work properly. Even if it was my own I might think twice about throwing that kind of time and labor at a run of the mill van (no offense).
 
I say cut it out and see what you have. Is it going to be a rusty mess? definitely. Will it take more time and money than you ever thought? Most likley. Will the education that you gain from the experience outweight the time and cost? I think it will.
 
Yup, definitely look the complete vehicle over and gauge if there's other areas that are going bad before you spend your time and materials. Look at all the seams-see if there's rust growing. If you do replace the rotted section and want it to last you'll have to make sure the backside of this area is also coated well so corrosion doesn't start-especially the weld areas. Also determine what engineering design flaw caused the original panel to start rusting and correct the problem. You'll notice after you take enough of these internal failures apart that it usually starts at a seam that is open, open seams from the factory are fine for a little while with only the E-coating but they'll eventually attract and accumulate enough dust/dirt to hold moisture. Once the dirt is in there it will wick moisture in like a sponge, along with road salt.
 
crashtech;17437 said:
The reason I said what I did is virtually all people with a vehicle like that can't justify the expense to do the work properly. Even if it was my own I might think twice about throwing that kind of time and labor at a run of the mill van (no offense).
Click to expand...

ha ha, no offense taken;). And you're probably right. If it wasn't diesel, I'd sell it for a few hundred bucks. But I'd like to get the life out of the drivetrain.

At the same time I'd like to drive it for a while. But who knows. Maybe it's not worth the trouble and cost. I've got the tools to fix it from other things I use them for and I find fixing my vehicles to be a good way to save money. I do almost all my own mechanical work even the major stuff.

But body work is an art form and I'm sure takes lots of practice to make it look right and hold up in the long run. I'm not as concerned with it looking perfect. That'd be overly optimistic! But I'd like to get it to where it won't disintegrate on me either.

I'm guessing I should expect a few hundred in new panels?
 
I would cut the bottom 6" off up to the rocker seam and see what you have. You will likely have to clean out rocker as best as possible then rust proof as best you can. Then take a peice of sheet tin and build a patch to replace what you cut off and weld in. Guys here in the rust belt have been doing this for years, no big deal.
 
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