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03-27-2008 09:13 PM More Welding and Cutting
Tonight I finished fitting and tacking the rocker box to the floor. Once everything is fitted and tacked, the weld will be completed by jumping around and doing about a half inch at each jump.
The quarter panel bottom was cut away. I left the B pillar bottom intact just to keep one reference point. As you can see, there is a lot of rot here.
I am not sure if you can see what is going on in the last photo. The PO mud dauberred MIG wire in and then ground the outside to the body contour! What a mess.



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  [Entry #110]

03-22-2008 08:07 PM Installing the Rocker Box
The box was slid into place, hopefully for the last time. Judicious use of clamps, pry bars, and hammers wrestled the box into location. A Dremel tool with a thin cut-off disc and a air body saw got the gaps right. Tack welds were put it as the alignment was done. The important thing about the tack welds is to put enough good ones in so they don't break during the fitting, but can be readily removed if the realignment is required or (heaven forbid) the box would need to come back out.


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  [Entry #109]

03-22-2008 07:59 PM Finishing Touches Front of Rocker Box
The front brace was in a lot better shape than the passenger side was. At first, I thought I could clean it up and re-use it. After I got it off, it was apparent it was too badly pitted. A replacement was fabbed up from flat stock.
The second photo shows the finished front from the bottom side. Weld through primer was sprayed on and holes were punched for the spot welds which attach the floor section to the braces.
The last photo shows the top of the finished box front. POR-15 was painted on the portion which will be under the A-pillar and inaccessible after installed.



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  [Entry #108]

03-22-2008 07:49 PM More Prep of the Rocker Box
Once the floor cleared the brace, the box slid in. The outer panel was intentionally cut a little long. The distance from the tab to the cowl support was measured. Then the same measurement was transferred from the edge of the original rocker box to the green cut line shown in the first photo.
The second photo shows the fit after the cut was made on the green line. The A-pillar bottom was a little more rotten than I had first thought. A replacement piece for the soft area was fabbed up. The old piece is lying on the floor. Also note that some pie cuts were made so the "hump" could be moved to the center of the car, allowing the rocker panel to move out, lining up with the original better.



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  [Entry #107]

03-21-2008 01:32 PM Initial Fitting of the Rocker Box
A portion of the rocker behind the door needs to be removed in order to allow the rocker box to be inserted and then slid forward. These cuts don't have to be accurate, but I did want to leave as much structure as possible. In the end, I had to lengthen the cut by 2 more inches from what is shown in the first photo. The floor section needs to be removed as well. The inner panel has to have the lower section replaced, so I removed it with the floor.
The first fit shows that the floor on the inside of the "hump" is too low. It has to go on top of the floor brace, not under it. I attempted to reform it with a body hammer. I gave up in short order and cut a pie shaped piece from the inside side of the hump and will weld it once the final shape is determined.


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  [Entry #106]

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