Rocker Fairy??

[frogman68]

after cutting a grinding for the last 6 hours I think I am ready to weld it in but Mother Nature opened a cloud so I didnt bring the welder out . Does this look like its lined up to the bottom of the door correctly? the back needs to be adjusted (going up the door jam) but I think I can tweak it when I start welding♠

[Blazin]

(1) Where are your plug weld holes?
(2) Don't weld anything until you have your cab corner fitted perfect too.
(3) Screw everything in place with self drilling / tapping screws then weld.
Did you allready replace the inner rocker or is it in good shape?
Once you start welding its to late to tweak things.

Notice the plug weld holes along the bottom, also in the door jamb area of the rocker to weld it down to the inner rocker / floor board. Also trimed down, only use what you need.




Cab corner trimmed and plug weld hole drilled.


Screwed / clamped in place.






Welded.




Primed, & seam sealed.

[HAULIN IT]

Personally I would like to see a bigger gap between the rocker & the door. The variation in clearances when these trucks were new was not great, now that they have been tweaked, sagged & everything else... a little more couldn't hurt. We haven't mentioned the aftermarket parts variations yet either. I like to use the door that will be used when the job is done for aligning the rocker/cab corner, this way at least until the door needs changed for some reason you have good gaps. Lorne

[frogman68]

Blazin I forgot to mention this is a Blazer no cab corner the (if they call it on a Blazer) inner cab corner is shot I am waiting to see if Chris can get them or I will have to make one I was going to plug weld it I was going to butt weld the new and old metal is perfectly lined up so no bump between the two

Thanks, I guess the rain shower was a good thing so I can tweak it before welding

Haulin how much of a gap would leave it is just screwed in for now

[hotrod24]

nice work man i hope i can do that good

[HAULIN IT]

1/4", about twice what you have by the looks of it. There is no need to butt weld where your attaching the rocker, except the last 2 flats that goes to/under the cab corner/side panel. If you cut the new rocker (as low as possible) line it up, draw a line around it on the old panel, then cut the old panel off 3/8" or so to the inward side, this will leave a "backer" to weld to. On the sharp corners, (once you have a few tacks on) just cut through the old rocker at the edge of the new rocker 1/4" or so going each way from the corner & tap the new panel downward a little & weld it up. I do as much of the welding from the bottom as possible (bottom lip, going up the back-inner edge of the cab corner ect.) welding & grinding  it isn't as much fun, but no holes to fill & finish. Have Fun! Lorne

[oldwhity]

I heard it was around 3/16" but not quite sure.
Blazin, are plug weld holes another way to "spot weld" when you don't have a spot welder?

[frogman68]

1/4", about twice what you have by the looks of it. There is no need to butt weld where your attaching the rocker, except the last 2 flats that goes to/under the cab corner/side panel. If you cut the new rocker (as low as possible) line it up, draw a line around it on the old panel, then cut the old panel off 3/8" or so to the inward side, this will leave a "backer" to weld to. On the sharp corners, (once you have a few tacks on) just cut through the old rocker at the edge of the new rocker 1/4" or so going each way from the corner & tap the new panel downward a little & weld it up. I do as much of the welding from the bottom as possible (bottom lip, going up the back-inner edge of the cab corner ect.) welding & grinding  it isn't as much fun, but no holes to fill & finish. Have Fun! Lorne

Doh dont have enough material to drop it a quarter of a inch I guess thats why you shouldnt butt weld
My stupid thinking was if its butt welded you only have to grind the weld down and then maybe a scratch coat of Bondo.

Here is the first thing I fixed on the body I just threw that primer on it because rain was coming







figured if I over lap then I will have to put more bondo on it I tried flanging the pieces but still didnt meet flush so I went to butt welding

[Blazin]

Well in your case the cab corner would be the lower section of the rear quarter. I should have seen that in the pics! As far as the spot up high I would have butt welded that too. It s bad spot to have build up of material on. Agreed on the gap. Should be about twice what you have. Yes plug weld holes take the place of spot welds. Spot welds are done without a hole. In order to duplicate them with a mig you need to drill the holes.

[oldwhity]

That's what I thought, thanks

[frogman68]

Ok take 2 on the rocker went out and readjusted is this better ? Back by the door is still a issue but if I move it back it throws the rest off once I start tacking it I might try tapping it with a ball peen to see if it will go back





Thanks
Brian

[Blazin]

Ball Peen??? Don't you mean body hammer??
that you should be able to encourage back even with it just screwed in place. A little relief cut down the high point and inch or two might help as well. then just stitch it back closed while welding.

[frogman68]

Ball Peen??? Don't you mean body hammer??
that you should be able to encourage back even with it just screwed in place. A little relief cut down the high point and inch or two might help as well. then just stitch it back closed while welding.

20 oz ball peen is my body hammer I think that part is figured out the replacement part of the rear quarter has a 90 lip on it , it wont go in unless I cut that part of the rocker off

[Blazin]

I wouldn't cut it off. I would slice it down enough to push it back. The plug weld the face of the patch to it. You should invest in a body hammer set, with some dollies. Well worth the money.

[frogman68]

I wouldn't cut it off. I would slice it down enough to push it back. The plug weld the face of the patch to it. You should invest in a body hammer set, with some dollies. Well worth the money.

You wouldnt consider these "body hammers"?



I was thinking of using this if it dont go right




I will take a trip to harbor freight today thanks for the tip

I cant put a slice in the rocker it goes from the top of the rocker to the bottom the positive of cutting it off is I can get the door gap right at the bottom were the rocker and quarter panel come together.  Since I have to make a piece like a inner cab corner that is where I will have the rocker and quarter panel connect together.

I have the rocker on hold for now I am debating if I should recut it since I have a another one for the Beast project that is on hold

Anyone ever use this ?



since there is so much rust if this will bust the spot welds