So I am going to be replaceing the rockers on my 87 k5. What advice can you guys give me ? Also do you have to remove the fender to do this ?
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Rocker panel replacment advice and question
- Thread starter dheavychevy38
- Start date
I just finished up replacing the rockers on my 87. It wasn’t a hard job at all it just requires some patience and a little thinking. I have some experience fabricating and replacing rusted panels but nowhere near as much as the pros around here have so I'm only going tell you what I did.
There are a bunch of posts here on CK5 regarding rocker rep
lacement and I have included 2 that helped me out when I did my repairs.
Kstanbach's rig
http://coloradok5.com/forums/showthread.php?t=303645&highlight=rocker+panel+replacement
mudhound72's rig
http://coloradok5.com/forums/showthread.php?t=131319&highlight=rocker+panel+replacement
I'm not 100% if you absolutely NEED to remove your fender but I did. I think the only way to completely replace the rocker panel is if you remove your fender. Chances are, that the inside of the fender and the inner fender are rusted out on you rig too if you need to replace your rocker.
I bought replacement inner an outer rocker panels from LMC and they worked well. If I were to do the process all over again, I probably wouldn’t purchase the inner rockers, I would make my own.
You’re going to need many cut off wheels half as many grinding wheels, a welder (I used a 90amp flux core mig), a spool or 2 of wire, some primer, some paint and patience.
I would suggest removing the door and the fender, holding the new rocker panel up against the old rusted panel and tracing a line around the new panel on to the old panel with a sharpie. Pull the new panel off and stick it back on the old rocker to check your marks. This is where I have heard of people bracing their doors such that the body doesn’t shift when you cut out the old rocker. I didn’t brace anything; I used a floor jack under the bottom door hinge to hold the cab in place while I cut the old panel off. The floor jack kept everything lined up while I positioned the new panel in place and tacked it in. Make sure you account for the thickness for the sharpie marker and the distance that the marker was away from the new rocker when you traced it prior to cutting. Welding gaps takes forever and can be prevented. Once the old rocker has been cut off via cutting wheels, you can tack the new rocker into place. Remember to tack the rocker in and then check door fitment. Once everything lines up and the door shuts, remove the door again and burn in your rockers. You will burn thru the new rockers, it’s going to happen. They are pretty thin just take your time and don’t spend too long in one spot. Move your welds around so you don’t warp the rockers and screw up your door fitment. Take your time. Once you burn your rocker in, grind the welds down and spray some primer on them.
I installed the inner rockers on the outer rockers first prior to welding them to the cab. Like I said earlier, if I were to do it again, I would just fabricate my own inner rockers. Once you have your outer rockers installed it is now time to install your inner rockers. I would just use some 16ga flat steel to close in the rockers. Some people here leave the inner rockers off to prevent the rockers form rusting out again however I closed mine in for added integrity. Just remember to drill drainage holes in your inner rockers to get rid of any trapped water that may accumulate. You will be able to "shoot in" some rubberized undercoating thru these drainage holes to protect the insides of both rockers.
Chances are that if your rockers are toast, your floors and cab corners aren’t too far behind. Have you checked under your carpet?
Here was my rig a mere 2 weeks ago.
Just take your time and don’t rush anything. Measure many times before you make your cuts. Once you remover one of your rockers you’re going to feel like what the heck did I just do? Don’t worry; it’s going to look great when it’s done.
Good luck,
Matt
There are a bunch of posts here on CK5 regarding rocker rep
lacement and I have included 2 that helped me out when I did my repairs.
Kstanbach's rig
http://coloradok5.com/forums/showthread.php?t=303645&highlight=rocker+panel+replacement
mudhound72's rig
http://coloradok5.com/forums/showthread.php?t=131319&highlight=rocker+panel+replacement
I'm not 100% if you absolutely NEED to remove your fender but I did. I think the only way to completely replace the rocker panel is if you remove your fender. Chances are, that the inside of the fender and the inner fender are rusted out on you rig too if you need to replace your rocker.
I bought replacement inner an outer rocker panels from LMC and they worked well. If I were to do the process all over again, I probably wouldn’t purchase the inner rockers, I would make my own.
You’re going to need many cut off wheels half as many grinding wheels, a welder (I used a 90amp flux core mig), a spool or 2 of wire, some primer, some paint and patience.
I would suggest removing the door and the fender, holding the new rocker panel up against the old rusted panel and tracing a line around the new panel on to the old panel with a sharpie. Pull the new panel off and stick it back on the old rocker to check your marks. This is where I have heard of people bracing their doors such that the body doesn’t shift when you cut out the old rocker. I didn’t brace anything; I used a floor jack under the bottom door hinge to hold the cab in place while I cut the old panel off. The floor jack kept everything lined up while I positioned the new panel in place and tacked it in. Make sure you account for the thickness for the sharpie marker and the distance that the marker was away from the new rocker when you traced it prior to cutting. Welding gaps takes forever and can be prevented. Once the old rocker has been cut off via cutting wheels, you can tack the new rocker into place. Remember to tack the rocker in and then check door fitment. Once everything lines up and the door shuts, remove the door again and burn in your rockers. You will burn thru the new rockers, it’s going to happen. They are pretty thin just take your time and don’t spend too long in one spot. Move your welds around so you don’t warp the rockers and screw up your door fitment. Take your time. Once you burn your rocker in, grind the welds down and spray some primer on them.
I installed the inner rockers on the outer rockers first prior to welding them to the cab. Like I said earlier, if I were to do it again, I would just fabricate my own inner rockers. Once you have your outer rockers installed it is now time to install your inner rockers. I would just use some 16ga flat steel to close in the rockers. Some people here leave the inner rockers off to prevent the rockers form rusting out again however I closed mine in for added integrity. Just remember to drill drainage holes in your inner rockers to get rid of any trapped water that may accumulate. You will be able to "shoot in" some rubberized undercoating thru these drainage holes to protect the insides of both rockers.
Chances are that if your rockers are toast, your floors and cab corners aren’t too far behind. Have you checked under your carpet?
Here was my rig a mere 2 weeks ago.
Just take your time and don’t rush anything. Measure many times before you make your cuts. Once you remover one of your rockers you’re going to feel like what the heck did I just do? Don’t worry; it’s going to look great when it’s done.
Good luck,
Matt
