Next set of pictures show what was left once I started cutting things away. The drivers side wasn't as bad as the passenger side. The passenger side had rotted from one end to another, and the inner rail with the circles was rotted as well. So I started with the easy side, hoping to gain some experience to help with the "bad side."

 

Next step fit the outer rocker panels. Unlike the other poster who did his own rehab see: Ridgeline Rusty Rocker Repair The guy in the thread used 1/8th channel steel, which I didn't want to buy as I had the sheet steel and welding the thicker steel to thin steel was beyond my ability. So I decided to buy the outer rocker panels and fit them on. I bought the cheaper non-oem ones because I figured I would be trying to put humpty dumpty back together and close enough was going to be good enough. Besides the cheaper ones came with the lower quarter panel pieces. I also replaced the outer rocker panels so I could have something to line up the inner rocker panels with. I took the rear door off to make room. I marked everything as best I could and broke out the plasma cutter. As you can see I didn't use the portion of the panel that folded over the "step" . I pre drilled the holes along the bottom ridge of the panel and I tacked it in.

 

I fitted the quarter panel piece in and went to work on the inner rocker panel. Where ever I could I bolted and welded. I utilized the supports and cross members where ever possible. I cut the sheet steel to length and width. I also cut a dotted slot so I could bend the steel to marry up with the ridge of the outer rocker panel. I bolted and welded the outer rocker, the inner rail with the circles and the outer rocker together.

 

Did I say what a smart move it was to buy the plasma cutter. boy it saved time and it was slicker than you know what through a goose. Once I got everything together on the driver's side I slapped some primer on it. I saved all the grinding and finer welding for later.

 

Armed with a little knowledge and a little confidence I planned a way forward on the bad side. The problem I had was the inner railing with the circle cut outs was practically non-existent. So used some thinner metal and cut out a couple of pieces to fit on the inside. I used the dotted slot line for my bends and I fitted the new "sleeve" in. I bolted where ever I could so the metal would be drawn together for a better weld. As you can see I bent the metal so there was a ridge to marry up with the outer and inner rocker panels. I also over lapped where ever I could and bolted/welded.

 

With the inner rail done, I fitted the outer rocker panel and lower quarter panel piece and tack welded as I did on the other side. I then carefully figured out how to fit the inner rocker panel pieces in. I used the supports where ever I could, I had to weld/bolt some pieces to the side so I would have something to weld to. I over lapped and bolted where ever I could. (Once things were fitted and bolted I welded the nuts on so they couldn't loosen up.) I also put in some straps from the inner (existing metal) to the ridge and bolted and weld that in. As you can tell from the photos, the bottom ridge has three pieces of metal that come together the outer rocker, the inner "rail" and the inner panel. Did I mention how that plasma cutter was good investment.

 

Okay, as I was going along I was priming and painting the metal. I spent a ton of time grinding and rewelding gaps. I bought a can of what used to be called tiger hair and slathered it along all the inner rocker weld lines to close up any gaps. I also used it on the outer rocker panel weld lines. I then sprayed bedliner over the inner rocker panel and outer rocker panel. This project was about getting the truck back on the road, looks were secondary, but all in all it looks ok.

 

Ok final post I think. After I was done with the body work, I had to replace the front exhaust pipe (Y pipe) Be-careful who you buy it from, I got one on ebay that would not fit around the oil pan. Buy a Walker brand it fit like a glove. Take aways, always wear gloves,safety glasses, googles, shields, respirators, proper welding safety gear, proper glasses for the plasma cutter. Did I mention how much that plasma cutter helped, could not have done the job without it. Oh by the way I have very little experience in welding or any type of metal fabrication. I just tried to use common sense and make everything tight and right. All told with the exhaust pipe it took me the better part of three weekends Friday night, through Sunday. It was hot dirty work, I went through two pairs of welding gloves, (note to self don't skimp on the welding gloves.), a half a dozen respirators, ruined at least three shirts and a few pairs of cheap gloves and a good pair of leather gloves. I had a little hiccup at inspection, mechanic drove it into the bay and the engine light went on, some evaporation purge valve. My mechanic was impressed with the work. But now I am good for at least a year and I just crossed over 220K miles. Best part, I told my wife See I told you I could do it.... oh and not car payments. All in all it cost me under $500 for rocker panels, welding wire, grinding discs, primer, paint and bed liner, not counting the plasma cutter and I had the steel for free.

 

You deserve a medal for bravery. I salute you.

 

Nice buddy!! Thats some great work!!

 

Very nice work considering it was a rust bucket heading to the junkyard. Good for at least another year. So what's the total with buying the tools to do it all ?

 

Approx $750 with plasma cutter. Steel I got for free it had been my shed for a few years.

 

That was a heck of an entry post!

It would be a pity if it failed the gas tank strap recall at this point.

 

Either they fix or I will lol

 

Very nicely done, @TOM15116. I never count tools as an expense for a job.