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rocker replacements

XJensen

XJensen

NAXJA Forum User
Location
Sacramento
Finished up my rockers a few weeks ago so I figure its time to share. The only thing I would do differently is to keep the rocker at a flatter angle. I placed mine at 4° while 1-2 would have been fine.

I took a similar approach as Eric with a few changes along the way.

Materials:
2x6 3/16
2x2 1/8
3" 1/8 stock
1 1/2" angle 3/16
1" angle 1/8
3" 3/16 stick for capping the ends of the rails

I welded everything up with 220 .030 flux core. It worked fine on the thin stuff just had to be very careful. This was my first welding project and I am very happy with it.

On to the pictures - old rails
2012-11-21_18-58-10_119_zpsc4d55c60.jpg


Got the doors and fenders off
2013-04-12_22-31-30_997_zpsfd727181.jpg


More to come....
 
you trimming the doors? or putting them below the doors? trimming the doors 2-2.5" was well worth it IMO. nobody even notices i did it either.
your jeep looks a bit cleaner than mine though, i can understand having reservations about it.
 
Vanimal said:
you trimming the doors? or putting them below the doors? trimming the doors 2-2.5" was well worth it IMO. nobody even notices i did it either.
your jeep looks a bit cleaner than mine though, i can understand having reservations about it.
Click to expand...

Yeah I trimmed the doors about 1.75". I agree well worth the extra effort. Looks almost factory.
 
You'll love this mod. I did the exact same thing. Looks good. Are you going to seal up the bottom of the doors?
 
I wanted to keep my seats stock and withe the belly pan I had two options. 3 or 5 legs to the rails. I felt 3 would be enough and honestly after mocking up 3 per side I really did not want to do 4 more.

IMG_20130608_130622_329_zpsa5b4828d.jpg


Also couldn't get a consistent depth for the rail do to part of the body near the front pass feet sticking out a little.
IMG_20130607_183923_316_zpse7faca46.jpg


IMG_20130607_183934_821_zpsaeb450d0.jpg

IMG_20130607_181613_893_zpscb107864.jpg
 
I feel ya. Looks good though. You paid attention to detail a little more than I did. I just took a BFH to that part near the front. And three legs is plenty. I have pulled my jeep over from a flop by the outer bar on my rockers. I had JCR rockers that had the side bar and I cut it off and used it on my rocker replacement. Glad I did honestly
 
Last edited:
1990JEEPXJ said:
I feel ya. Looks good though. You paid attention to detail a little more than I did. I just took a BFH to that part near the front. And three legs is plenty. I have pulled my jeep over from a flop by the outer bar on my rockers. I had JCR rockers that had the side bar and I cut it off and used it on my rocker replacement. Glad I did honestly
Click to expand...

I will be adding an outer bar at a later date as well. Should be done by moab. Without it on my current rails my doors would look much worse
 
i just bent some 1/8" steel to put on the bottom of my doors. nobody really notices, and it offers some decent lower door protection. one tip, throw a few tack welds where the door skin pinches around the door frame. once you cut the bottom, the door skin becomes loose and the whole door is flimsy.

looks good man!
 
Mocked up and burned in the legs. They cover from the top edge on the side and wrap under the rail too.

IMG_20130608_161033_473_zps14038ea4.jpg


I took my time to get everything lined up.
IMG_20130612_232250_208_zpseacaafb2.jpg


I did wanted to cut two holes per leg, one in the floor and one in the side but that ended up being a waste if time

IMG_20130612_232408_652_zpsf6880f45.jpg
 
Testing the welder on 3/16 and the scrap from the rocker. Faster wire speed and lower heat worked well for me. I was able to get good penitration on the 3/16 and not burn the thin stuff much.

The welds on the bottom are higher heat less speed. I turned up the speed and down the heat as I went up. Like I said this is my first welding project so welds aren't going to be pretty to begin with. But I did get better and better.

IMG_20130613_185302_043_zpsf96fba8a.jpg
 
Looks good :D

If you can weld those on nicely then you have a good start, imo those were the hardest thing to weld on anything I have done to my jeep
 
I'm gonna keep an eye on this one......
(subscribed)
 
Thanks guy I'll post more up later.

Another lesson learned was to keep track of what door shims went where. Got lucky on the first one but the others took a few tries to get close.
 
XJensen said:
Thanks guy I'll post more up later.

Another lesson learned was to keep track of what door shims went where. Got lucky on the first one but the others took a few tries to get close.
Click to expand...
YES.

even with the right stack of shims, getting the hinge lined up so that the door properly seals can be a real B. what i did was hit each hinge with some spray paint, that way it all goes back together exactly the same.
 
Welds got better after practice so I burned it all in.

IMG_20130613_211058_727_zpsca4c9b36.jpg


It took a mini sledge and folded over the pinch seam to go under the floor and pounded the corner of the floor until it was relatively straight. I drilled holes in the 1.5" angle to plug weld but ended up not using the holes. The bottom edge was jacked firmly to the floor and notched to fit against the legs. I felt it was enough to weld the top edge to the three legs and to use the 1" angle to tie it in to the bottom of the legs.

IMG_20130607_201430_664_zpsf4fec12d.jpg


IMG_20130711_202129_160_zps13edf855.jpg
 
I figured I would hit the 1.5" angle more than the rockers so I decided to take a piece of 3" stock and tie in the bottom of the angle to the rocker. It really made everything look nice and clean too.

IMG_20130712_171925_994_zps425e1b83.jpg
 
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