Hi Guys,

I've got rust on the inner and outer rocker panels on my '69. The outers look like this:

http://i268.photobucket.com/albums/jj8/paulschevelle/rocker%20rust/driverouter.jpg
http://i268.photobucket.com/albums/jj8/paulschevelle/rocker%20rust/driverouter3.jpg

I have a replacement panel. Would it be better to cut a patch and weld it in, or to replace the whole panel?

The inners are bad too:

http://i268.photobucket.com/albums/jj8/paulschevelle/rocker%20rust/driverinner2.jpg
http://i268.photobucket.com/albums/jj8/paulschevelle/rocker%20rust/driverbrace.jpg
http://i268.photobucket.com/albums/jj8/paulschevelle/rocker%20rust/passinner.jpg

The last two pictures show where the floor brace also rusted away along with the inner. I can't see how to easily separate the inner to replace the whole length, so it seems that welding in patches is the way to go.

As for the floor brace, can I just replace the ends is the rest of the old brace is sound?

I really appreciate any help and advice you can give me.

Thanks,

Paul

Replace the entire panel and repair the inner it's an easy fix , if you need photo's on step by step I'll post them for you, as for the ends of the braces they are available

Thanks Kevin, those pictures would be a big help.

Here's some shots of the replacement panel:

http://i268.photobucket.com/albums/jj8/paulschevelle/rocker%20rust/newpanel1.jpg
http://i268.photobucket.com/albums/jj8/paulschevelle/rocker%20rust/newpanel2.jpg
http://i268.photobucket.com/albums/jj8/paulschevelle/rocker%20rust/newpanel3.jpg

I thought it might be easier just to patch, so I wouldn't have to get into the quarter panel. Also, it looks like the outer rocker, floor pan, and inner rocker come together on the underside, and I'm not sure how to get them apart.

Thanks again,

Paul

Hey Paul, how are the floors in the car, if the brace is rotted at the end are you sure the rest of the floor is OK? The 65 that had the same rot on the brace had a junk floor as well. I would replace the entire inner and outer rockers since you have them already. Call me if you like sometime.

Ok, you need to get at the spot welds and drill them out I made markings on my photo's so you can see where the spots are(or a general idea) and also where to use a sawzall , once you get the main part cut out you can see where you have to separate the sandwiched panels, I used an air chisel to get in between it is a good day's work but it's worth it to do the job right
It appears I already used these photo's on another rocker post and it won't let me post them twice so here's the link, hope this helps you out
http://www.chevelles.com/forums/showthread.php?t=285560

Paul,
before you start welding in the new rocker pre drill your holes along the bottom of the panel, I used an air punch on mine but they can be drilled the dotted line is just to give you an idea

I'm with Dave Seitz on this one. I suspect your floors will need some work.

Have you seen these?

http://cgi.ebay.com/ebaymotors/FULL-FLOOR-W-BRACES-CHEVELLE-68-69-70-71-72_W0QQitemZ260465525896QQcmdZViewItemQQptZMotors_ Car_Truck_Parts_Accessories?hash=item3ca4f48488&_trksid=p4506.c0.m245

I'm with Dave Sietz on this one. I suspect your floors will need some work.

Have you seen these?

http://rover.ebay.com/ar/1/711-53200-19255-0/1?mpt=1570189938&adtype=1&size=1x1&type=3&campid=5336121898&toolid=10001 http://cgi.ebay.com/ebaymotors/FULL-FLOOR-W-BRACES-CHEVELLE-68-69-70-71-72_W0QQitemZ260465525896QQcmdZViewItemQQptZMotors_ Car_Truck_Parts_Accessories?hash=item3ca4f48488&_trksid=p4506.c0.m245 (http://rover.ebay.com/rover/1/711-53200-19255-0/1?type=3&campid=5336121898&toolid=10001&mpre=http%3A%2F%2Fcgi.ebay.com%2Febaymotors%2FFULL-FLOOR-W-BRACES-CHEVELLE-68-69-70-71-72_W0QQitemZ260465525896QQcmdZViewItemQQptZMotors_ Car_Truck_Parts_Accessories%3Fhash%3Ditem3ca4f4848 8%26_trksid%3Dp4506.c0.m245)

That's a nice panel! But if the floors are soft I'd do the inner and outer rockers 1st to give the car some structure

Amazingly the floors are OK. They have some surface rust but are otherwise solid. The braces are Ok too, except for a couple ends.

Epoxy primer the inner parts before you install them.

Paul. I would be willing to come out and take a look if you need to.

Heres how they tie in if it will help. Also a second set of eyes like having Chris come over is always a good thing, he will see things you don't.

http://www.1969supersport.com/floorpn8.html

Rob

Am I wrong or are the quarters actually quarter skins that are wrapped around the rocker.That could complicate things.

Yes! You are wrong. The quarters are welded to the top lip of the outer rockers then leaded or filled in.

I stopped over and now Paul is not talking to me. What I just noticed a few things that made a little more work for him, now he is upset. OK so it is a LOT more work then he thought.

I stopped over and now Paul is not talking to me. What I just noticed a few things that made a little more work for him, now he is upset. OK so it is a LOT more work then he thought.

He will thank you later on down the road.:D

Yeah, thanks Mr. Sunshine. Instead of patching rockers I'll be be cutting out floors, braces, wheelhouses, and quarters. The only thing Dave didn't complain about was the roof (although come to think of it, he was so busy spreading joy about the rest of my car he probably didn't see it).

Rob,
You are my sunshine, my only sunshine, you make me happY!!!!

Paul, just take out the outer, fix the inners etc. I'm doing it now, no big deal. Rob has some good pics.

Paul, I forgot to mention that it could made into a convertable with a little elbow grease.

Your inners will look worse once sandblasted. If your floors are shot then I would get a new 1 piece floor with the rockers pre-installed.

http://www.restorationperformance.com/servlet/the-103382/1968-dsh-69-Chevelle-Floor-Pan%2C/Detail

Here is a pan that has all that you need. It will repair all without as much work.