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Inner/Outer rocker panel replace

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  #1  
Old 07-11-2018, 06:07 PM
M3rc
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Inner/Outer rocker panel replace

I've been lurking on this forum for a while and want to start out my first post by saying thank you to all of the contributors on here. You've saved me a boat load of cash and frustration fixing my '01 Ex 7.3 by myself. That being said, my ex is a midwest one which has the inner and outer rocker panels rusted out so bad I can't even mount running boards on it. I purchased frame mount nerf bars just to realize that I don't want my kids legs falling between the step and the rusted out outer panels. My wife's one condition on owning this thing is that I put running boards on it. So my questions are:

Inner Rockers(Floor support)
1.)No one sells inner rocker panels(floor support) anymore. Would a straight piece of sheet metal suffice(with some drilling for appropriate holes) work or are there some complicated bends that I'm missing? Looking underneath mine of what's left, it doesn't appear so.
2.)Since I don't have a spot welder, would I need to do a long seam weld along the whole cab?
3.)Is there a risk of collapsing the body once I get the inner rocker off?
a.)if yes, then should I replace it in sections and then weld the whole thing together or any suggestions on how to support it?

Outer Rockers
1.)I've found the rear outers on rock auto and other places. For those that have replaced the front outers, a pillar and b pillar. Which cab is most like the excursion for replacing those? I realize none have anything like the c pillar.
2.)Do the outer rockers over lap and bend over the inner rocker?(yes, it's rusted that bad.)

I realize to many of you, I should just sell it and get a different one to save the headaches. This decision isn't just a financial decision but something I just want to do.
Thanks in advance to any responses.
 
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Old 07-12-2018, 09:15 AM
CanyonRider
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This pic may help you visualize what's going on. Unfortunately, I didn't take any better pics when I replaced the outer rockers and quarter panel. My inner rockers were fine - they don't appear too difficult to fabricate.



CR
 
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Old 07-12-2018, 09:26 AM
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I have to do similar to mine unfortunately. I was wondering how different the SD pickup inner rocker panel is from the excursion?
 
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Old 07-12-2018, 09:35 AM
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Not sure about the inners....I'm hoping I don't find major issues when I tear mine apart. Here's a few good threads showing some good work done by others specific to rockers:

https://www.ford-trucks.com/forums/1...002-v10-4.html

https://www.ford-trucks.com/forums/1...-rust-ugh.html

I actually just purchased the materials to do the rear outers. Here's what I got:

Rockers:
Amazon Amazon

Panel Adhesive:
Amazon Amazon

Ospho:
Amazon Amazon

Spot Weld Cutter:
Amazon Amazon

Still need to get the cutter and to decide on paint for the rockers.

Good luck!
 
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Old 07-12-2018, 02:23 PM
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Just in case anyone missed it, this may save you some time and rework.

https://www.millsupply.com/auto-body...ord-excursion/
 
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Old 07-12-2018, 11:14 PM
M3rc
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I hadn't noticed the b pillars before. Thanks! I won't start this project till the end of the month, but I'll definitely post a follow up with pictures.
 
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Old 07-16-2018, 02:04 PM
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for the front rocker panels, it looks like the SD and excursion use the same. I assume getting a front set for a SD should be fine then, correct?
 
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Old Today, 11:01 AM
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I have started working on mine. Got the front driver rocker off. I have to repair the inners also. I was hoping to get a SD crew cab inner but looks like only supercab and regular cab inners are made that I can find. I guess flat stock 16 gauge will have to do.
 
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