How To Patch Rocker Panels

Rocker panels are one of the most vulnerable parts of your vehicle when it comes to rust and damage. They are located beneath the doors and serve as a barrier between the passenger compartment and the road. Rocker panels can be made of various materials, but most cars have them made of steel. Over time, the rocker panels can become rusted or damaged due to road debris, moisture, and other factors. In this article, we will show you how to patch rocker panels to keep your car looking great.

What You'll Need:

- Welder

- Angle grinder

- Wire brush

- Sandpaper

- Metal patch panels

- Metal cutting shears

- Protective gear (safety goggles, gloves, etc.)

Step 1: Remove Damaged or Rusted Rocker Panels

Before you can patch your rocker panels, you need to remove any damaged or rusted areas. Depending on the extent of the damage, you may need to remove the entire rocker panel. To do this, use an angle grinder to cut away the damaged area, then fit the metal cutting shears into the cut and work along the rocker panel. Remove the excess metal until you have a clean, square hole that is ready for a metal patch panel. After cleaning away debris, check for any rust and clean the metal thoroughly down to bare metal using a sandpaper.

Step 2: Cut Metal Patch Panels

Measure the dimensions of your rocker panel hole, either by copying the opposite side or by using a measuring tape. Using metal cutting shears, cut out a patch panel that is slightly larger than the hole in your rocker panel. Ensure that the patch panel fits snugly within the hole, and trim any rough edges.

Step 3: Weld The Patch Panels

Start by placing the patch panel inside the hole and welding its outline to the surface of the remaining rocker panel that is still in good condition. Make sure that the patch panel is firmly in place before you begin to weld. From there, you can work your way around the perimeter of the patch panel by welding it to the original metal. If you find you need a dolly or hammer to contour the metal, that's okay. You can achieve perfection in the grinding step.

Step 4: Finishing

Once the welding process is complete, use an angle grinder to smooth the welded joints and then apply a rust preventative solution or paint to prevent oxidization.

Conclusion

In conclusion, patching rocker panels is a job that requires some experience, skill, and the right tools. With patience and proper attention to detail, you can save a significant amount of money repairing rocker panels yourself. It is essential to address rocker panel damage or rust immediately before it spreads to other areas and weakens the entire vehicle's structure. By following the steps outlined in this article, you can successfully patch your rocker panels and restore your vehicle to its original condition.

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