I haven't removed the plastic cover but I've ripped out massive amounts of rust outboard of the bottom pinch welds.
I'm trying to learn what I'm dealing with. Here are my suppositions:
- The rocker structure is a box
- The outboard wall is double construction:
a) Outer is a massive panel which includes rockers, pillars, sills outlining the doors
b) Inner is a rocker size w/top pinch welds to the door weatherstripping
I'm pretty sure both outboards are gone (but are solid above the plastic cover.)
So the question is What are my options:
- Cut an entire assembly from Pull and Pay
a) from Ford
b) buy repair panel (whose?)
- Outer: buy repair panel (whose?)
- Crude Fab slop job if can keep behind plastic cover.
- Ignore repair of inner rocker (my bad)
I know there is someone selling inner and outer kit on eBay for $240, but P&P is $60 for both AND they would be correct and possibly a thicker gauge.
If I fab, I would use 18ga or 16ga.
I would also make every effort to keep the fab behind the plastic cover so painting is not an issue. (could achieve same thing by P&P cutout - pieces would not need to be formed. Finding a good one might be difficult - wouldn't be surprised if the inner panel rots away before the outer???
Thoughts, suggestions welcome - also which repair panels are the thickest.