This pertains to me splicing in a new rocker.OK, I have the rocker fit in and now I see the profile of the new one doesn't exactly match the original. The radius where it bends and goes to the large outside radius is about 1/16" on the original, and about 1/8" on the replacement. The large radius which makes up most of the outside shape of the rocker doesn't match either, its flatter on the replacement. I have it secured with 4 sheet metal screws and when the top is on the floorpan and the bottom is squeezed against the inner rocker, the profile just doesn't quite match up .What are you supposed to do? All I can think of is a 12" strip of filler blending the 2 profiles together and hope nobody notices. :(

That is about it, unless you can change the shape of one of them to match. The choice being the old one of course being that is the smaller of the two. That is if I think you are replacing the majority of the rocker. If that is the case, you could "massage" the old on with a body hammer to flatten out that larger area that has the "crown" in it. Then, you can using a body hammer "square" off the edge so it more closly matches the new part.

If your new part is only small portion of the rocker, you could bend the crown the old one has and sharpen the corner that is too large a radious.

If you gently do this, just gently experiment on the left over piece of the new rocker that you are not using, you may find you can get it a lot closer with only a little work. You still are going to need some filler work, but maybe you can save yourself some if you spend a little time on the metal.

Thanks very much for the help! Just wanted to be sure I was on the right track.

Steve