Hi all -
I have a 2003 Expedition that has the bottom part of the rocker panels completely rusted out on the bottom of the truck. Wondering if anyone has repaired those and if there is a part # for it? It is not the curved rocker panel itself (under the doors), but underneath the truck that connects to the rocker panel with spot welds. You need to be under the truck to see any of it. I pulled off my running boards to inspect the damage and it was all rotted out and I could pull it out by hand.

thanks for any info!
Dan

 

Its hard to understand the part your talking about. I have been chasing rust on my 03 Gator for a while also. I usually cut out the rust, treat the surrounding areas with Ospho or simalar product. Then weld in a piece of cold rolled sheet metal.
If the part is bolt on i guess you can replace it with a junk yard part.

 

do you mean the piece behind the rocker panel with holes in it and the running board bracket kind of wraps around it and bolts on above it?

i just took my running boards off today and my rockers are toast. more like soggy toast actually. there was like an inch of dirt in there and I could poke right through the panel with a screw driver. the part your talking about, on mine, just had some surface rust. im going to cut out my panel, grind down what I can, and under coat from the door jam down underneath and in that cavity that the panel was covering.

post some pics if you can.

 

I got my 04 expedition for way too cheap, and the water leaking in is probably why. It's getting to the rear seat floorboards and rusting out the rocker panels under the rear doors. I'm gonna weld in patch panels, but first I gotta find where the water is entering. Could it be the roof seam? I don't think it would be the rear side windows, would it?

 

If you are looking for a quick fix thats looks great. Rustrepairpanel.com - Rocker Panel Kit

 

It's too bad they don't so much as show a picture of the product. Not too many people want to buy something like that without knowing what it looks like.

On another note, I repaired both sides of mine using a roll of Home Depot flashing trimmed using tin snips, some self-tapping screws, a can of primer and one of paint. Everything cost me under 20 bucks. The site above wants $60 per side just for the panel, then shipping, then you still have to paint them.

 

It was only $60 for a kit, which was 2 panels and self tapping screws. Similar to what your doing. I think these are thicker, and they are bent well. It only took an hour to do both sides. My truck is black, and they were already black so it worked out well. I passed state inspection and I got my license plate. Woohoo!