What's the best way to fix rusted out rocker panel?

[Johnny V]

Hi All,

My '89 Cherokee has a rusted out rocker panel under the passenger rear door...see picture:

http://home.comcast.net/~johnnyv/jeep_rocker_rusted.jpg

As much as I would like to replace it with a box steel rail I don't really have the time to do so or the bucks to buy a welder. Anyway what is the best way to fix this?

In another thread I read 5-90's suggestion to use Rust-Mort which I will use and cut away all the rusted area, but after that do I just get Bondo and apply it? Or do I add some structure to the opening like some rabbit-screen so the Bondo or other product will adhere and keep the shape of the rocker panel?

Is Bondo old news? Is there something better?

Thanks!

John V.

[Johnny V]

Just to add...I went to this post - http://www.naxja.org/forum/showthread.php?t=61654 - and got a lot of info about using Metal2Metal instead of Bondo. Thanks 5-90 again.

But still not sure how to apply it with a big opening like that in the pic?

Thanks!

[87xjco]

The bad news. Anything that you fill that with (bondo, fiberglass, miracle products, etc..) is not going to hold up more than a few months. It's just to far gone for non-metal, non-welding repairs. My .02c worth.

The good news. Alot of the work is already done for integrated rocker bars!

[Root Moose]

Some methods:

http://www.madxj.com/MADXJ/technical/technicalfiles/SRrockerPanels/RockerPanels.htm

http://www.madxj.com/MADXJ/technical/technicalfiles/JArockRails/Rockrails.htm

http://www.madxj.com/MADXJ/technical/technicalfiles/ARrockerPanels/RockerPanels.htm

[dizzymac]

Remove as much of the really bad stuff as you can, Rust-mort or Zero Rust the remaining, go to j.c.whitney.com and get a replacement rocker panel, $25 if remember right and just pop rivet or screw it over the old one, you'll have to play with it a bit but it will work.

I did this 'til I got around to cutting the new one in and welding it in place. I removed the doors on the passenger side,PITA, on the drivers side I fanagled it in without removing the doors. You might as well treat the new rockers with rust treatment too b-4 you install them.

[Johnny V]

I've been eyeing those links for a few years...believe me I would like to add rails, I just don't really have the time. Looks like it wouldn't cost that much.

Any other ideas to patch it up until next year when I can do the rails?

[Johnny V]

Thanks dizzymac, I'll have a look over at jcwhitney.com

[ren]

I got the drivers side off one XJ in the junk-yard for free, He said if I wanted it that bad I could have it if I cut it out. I love my cordless SAWZ-ALL.

[8Mud]

Remove as much of the really bad stuff as you can, Rust-mort or Zero Rust the remaining, go to j.c.whitney.com and get a replacement rocker panel, $25 if remember right and just pop rivet or screw it over the old one, you'll have to play with it a bit but it will work.

I did this 'til I got around to cutting the new one in and welding it in place. I removed the doors on the passenger side,PITA, on the drivers side I fanagled it in without removing the doors. You might as well treat the new rockers with rust treatment too b-4 you install them.

X2

I also cut the ends out, stuffed a few lengths of rebar in there and pumped about gallon and a half of fiber and resin mix in (fairly cheap at a boat yard) (used an empty caulking gun cartriage). Lazy mans rock rails. I crushed a whole door and just put 2 inch ding in my rocker panels.