Rocker rust repair


pjmcg

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Apr 15, 2021
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Philadelphia area
Thought I'd share some pics of my rust repair. Since it was on the driver's side I'd look at it every time I got in and couldn't wait til the weather improved so I could spend some time outside on this.

Seems like a previous owner left the top down enough that rain was pooling up and seems to have started this rust spot in an otherwise strange area for water to collect. The rest of the Jeep is in good shape in and out for 233k miles.

Started by cutting out the rusty section that included the bad spot and another small area I could see starting to develop a few inches away.
rocker rust spot.jpg


With some of the rust cut away
IMG_3585.jpg


New patch panel from 16ga sheet from Home Depot.
IMG_3608.jpg


View from below before I welded in a patch piece
IMG_3610.jpg


I was able to use the rounded corner from some steel angle to help shape the bottom of the panel to match and used some vise grips to bend it back to make the sharp crease. Used the flat area of my bench vise and a body work hammer to work out the vise grip marks and then ground the lower edge to make it match.
IMG_3597.jpg


Alot of grinding with a flap disc, some thin layers of body filler and coats of primer, and then some body color matching spray paint. I did some wet sanding and then applied another coat of paint before I ran out of the small 5 oz can I bought from Quadratec. Just got some more paint, so will be applying that and trying to blend it in a bit before some clear coat and more wet sanding.
IMG_3674.jpg


Also fixed a spot at the front fender
IMG_3614.jpg


IMG_3675.jpg
 

Rubicon88

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Sep 24, 2020
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Western PA....Altoona area to be exact.
Nice job. You have better skills than me. I would have sanded it, sprayed stop rust paint on and bought rocker guards to cover my mess. 🤫
View attachment 253427
You and most everyone else too.

When rust arrives...it never leaves. You just hope to control it.

Example...his repair job looks great...but...
I'll bet you ten wooden nickels where the welding was done rust shows up.
 
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someguysjeep

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ohio
i always paint the back of any patch b4 it goes on unless i will have access to the back side.
raw steel will not stay clean long. the welder will burn some away but most of it painted will be better than none of it painted/protected.
 
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Dunkut88TJ

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Knoxville, TN
Looks like a decent job, better than I could do! I discovered rust spots on both sides while swapping out my rocker guards that @TheBoogieman said he would use to cover it up 😂. Anyone have a rough idea what a decent body shop or welder would charge to cut it out? Not quite sure I’m ready to tackle welding haha
 

InOmaha

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Sep 26, 2019
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@Dunkut88TJ Cutting it out and preparing the area is easier than welding it. You might save money doing the destruction part of the job. Find a welder who can make it solid. Then skip the body work (but paint) and cover it up again.
 

Dunkut88TJ

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@Dunkut88TJ Cutting it out and preparing the area is easier than welding it. You might save money doing the destruction part of the job. Find a welder who can make it solid. Then skip the body work (but paint) and cover it up again.
Yeah I can manage to deconstruct things but welding…not so much