So in the next month or so I am going to delve into rust repair and patch panels for the rocker panels on the extended cab portion of my truck. I have never done this before so looking for advice on everything that I will need that I haven't thought of.

I am planning on cutting out as little material as possible. All my visible rust is in the bottom 2-3 inches of the panel, I am sure there is more in there once I cut into it. I plan on replacing from the body molding down so that way I can weld at the bottom of the molding and use that to hide any weld imperfections. I then plan on rhino lining my rocker panels all around the truck.

So once I get in there what will I need? I figured I will need a rust converter to spray around in there to prevent any more rust from forming and a good spray paint to put on top of that but I am sure I am forgetting something.

I am also looking for suggestions for a good DIY rhino liner for the rocker panels.

 

I used Duraliner inside my Bronco. It's stickier than the Rhino Liner (actual brand) I had sprayed in the bed of my '95 F-150, which is nice inside a vehicle because stuff doesn't slide around as much. But it's not as tough as the Rhino liner was, I've cut through it in a few places. So I don't think I'd recommend that for an exterior application like rocker panels.

The only other one I have any experience with is Herculiner, and very little with that. I coated an ammo can that I use to hold the jack in my Bronco and I coated my home made wood speaker boxes in the Bronco. Both have held up fine, but neither is a very tough application, so I don't know how well it would hold up on a rocker panel.

 

I know Line-x does a great job as a bedliner, so I assume it should work well as a rocker guard. I know it tends to be a pricier option, but you get what you pay for.

 

This is totally redneck but, several years ago I did extensive body work on my 95 F250. I just used regular undercoating but I mixed very fine sand in with it and brushed it on. It actually looked pretty good and I got a lot of comments about the rino liner. It's been over 5 years and it's still hanging in there. Now obviously there are better methods. I've thought about brushing on undercoating and spraying on the sand for a more even coat.

 

Look into AL's liner. It is the DIY version of SCORPION liner. I have VERY good results with it, I have even tinted it with good results

 

I've heard a lot of good things about raptor liner

 

Thanks for the suggestions, I will have to look into those. One I ran across was spray-linings.com. Has anyone seen or used these guys?

Any suggestions for the best way to prevent rust from reforming behind the patch panel once installed or anything I need to look out for/be aware of before I start cutting?

 

That right there is why I do NOT patch wheel wells. You can NOT get in there to properly protect your repair and rust will form INSTANTLY.

I do whole bed skins and glue them on, I use no welding