Rocker replacement with box tubes question

[obob22]

I am replacing my existing rockers with some 3x4 square tubing due to rust issues and about 1/2 of the pinch seam is rotted out, and there is not much solid metal left on the existing rockers, what is the best way to handle this?

I was thinking of cutting all the pinch seam out and welding a plate from the 3x4 to where the pinch seam used to be. What could happen if I do this?

I guess another fix may be to weld some angle iron to the non rusted part of the seam and extend the angle past the rotted part.

I just am having nightmares about driving down the road and a 3x4 sammich drops off my Jeep and wipes out my tires, or takes a bounce and destroys someones vehicle.

Its a 99 Cherokee Sport BTW

[yossarian19]

I would just cut out all the rust, level out a spot for the top of your box tubing, weld it all in and make sheet metal patches where necessary.

The pinch seam isn't anything special that I can tell. THe spot welds hold the body together... the seam itself isn't strong enough to stand up for itself.

[obob22]

Excellent! thank you very much, time to install the boxes

[aparke4]

the higher you go the more work and bracing that follows so plan accordingly after your rust removal and decide how you want to boatside/ rocker replace for your wheeling needs...

[Finaltheorem47]

I tied my box tubes in with the sub frame for more strength. The rockers provide a great jack point for the Jeep now. I also plan on using them as air tanks in the future. I ended up taking sheet metal to patch the original rockers up, then I welded the rockers up, but in retrospect, it probably would of worked better to just put the rockers in, then fill the gaps with sheet metal. Just remember to eliminate ALL rust as it is a cancer and if you only remove 90% of it, you can be confident that it will show its ugly face again in time.

[zr2toxj]

This is what we did:

http://img.photobucket.com/albums/v171/zealr2/XJ/Sliders003.jpg


We cut everything out and welded in a 2x6.

There's a bunch more pics here:

I love them.

http://smg.photobucket.com/albums/v171/zealr2/XJ/?start=420

[nmonderewicz]

zr2toxj i am about to do the replacement and i really like the 2x6 look i was wondering if u ran into any problems and how long it took u?

[machspeed]

I also did 2x6 rockers. Took maybe 3 hours per side, maybe 4.

The thing I did was to build the rocker first, capping the ends and all, then all I had to do was a little fitting and stitching it to the sheet metal. Weld in your supports and you can move the the other side.

The only issue with fitting is there is a bolt coming from the inside of the Jeep (lower seat belt bolt I think) and you need to cut a hole or make room for it in your 2x6 rocker so it sits flat. A 2 minute fix.

[guther66]

Those are some nice rockers zr2toxj