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deadbodyman 03-29-2013 08:04 AM

replacing damaged rocker 85 Iroc (unibody)
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normally I would have spotted the damaged rocker right away when I disassembled the car but time was limited so I started stripping the paint off the nose ,taking off what needed to removed as I went then went down the drivers side ,roof and deck I even pulled,and disassembled the door guts and replaced the hinge bushings...when I got to the very end the 1/4 and rocker there was a good bit of damage to the rocker that was poorly repaired and coverd up with the ground effect, rocker now im in the process of replacing it and thought you guys might enjoy watching someone else work for a while and seeing how its made and put together and learn something or even teach me something....

First I brought it over to my bud at the frame shop and had him check it out and pull if needed ,these T tops can be a nightmare when they get hit ,they twist fairly ez,he also aligned the front end for me...

The only way to do this affordably is with used parts so I went to the local U pullit and found what I needed and cut out (the chunk) with my 18v sawzall

deadbodyman 03-29-2013 08:18 AM

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Heres the rocker chunk with everything still attached ,the 1/4 bottom,hinge pillar,floor and all after I was done cutting it out from the junk yard......40.00 with an extra rocker cover (flair) it took three hrs and 8 batteries...:sweat:

tech69 03-29-2013 08:19 AM

wow! They did a great job at hiding it that's for sure. They might not have been a good tech but he's certainly a good hack. :)

btw, make more of these posts! I love your explanations on things. I'm always willing to learn more.

deadbodyman 03-29-2013 08:39 AM

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I'm not sure just how much I'll need so I'll remove each panel as if I was going to use every one...
I'm using a low angle drill bit insted of a spot weld drill because the saw type suck and the real good weld drills cost over 50.00 and I havent bought one in 15 yrs ,these drill bits work great just be carefull not to drill all the way through just one layer at a time...Theres a ton of welds to drill and theres always a few hiding somewhere that you'll miss no matter how hard you look.
In order to save time and make the drill last longer I start with an 1/8 drill ,find the center of the weld and drill a hole all the way through (in most spots except for the pinch weld at the bottom of the rocker and the where the door weather strip goes..We'll get to that and why later.
Basicly I'm taking the chunk apart piece by piece carefully just in case I need one of those pieces,I suspect I'll need part of the hinge pillar and possibly the inner rocker also...

deadbodyman 03-29-2013 08:48 AM

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I'll be doing this all by hand here a few handy tools I've found to work great for seperating the layers of metal,one of them is actually for shoeing horses.

deadbodyman 03-29-2013 08:56 AM

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This hinge pillar is a PITA ,the hinge reinforcement has three layers of thick steel to drill and seperate

deadbodyman 03-29-2013 08:59 AM

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Today I'll be getting the inner rocker off and then cutting out the old damaged one. see ya tonite..Oh ,heres the pile of metal I cut off all still in reusable shape

tech69 03-29-2013 09:24 AM


Originally Posted by deadbodyman (Post 1661369)
I'll be doing this all by hand here a few handy tools I've found to work great for seperating the layers of metal,one of them is actually for shoeing horses.

That chisel dolly thing looks awesome! Funny... I bought both steck seam busters and they just sit in my tool box. I might as well reshape the heads to something I'd like to use. Did you make that chisel dolly looking thing? That tool looks awesome with the reach it has.

S10xGN 03-29-2013 09:24 AM

Awesome write-up, thanks for sharing!


69 widetrack 03-29-2013 10:26 AM

Excellent Post and tutorial Mike, with the way you describe things you could be a color man at a football game.


deadbodyman 03-29-2013 01:11 PM

Thanks guys.....
the funny looking chisel with two heads is for shoeing horses ,found it at a flea market. I didnt know what it was for a few years after using it ...I love sorting through a pile of chiselsand hammers for anything unusual ,I found the long one at the same place I dont know what its original use was for but its one of the most used tools I have ,both will hold an edge a long time..Keep em sharp and they'll give you no problems...

deadbodyman 03-31-2013 06:56 AM

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here, I finally got the inner rocker seperated from the outer...The plan is to use the outer and straighten the damaged inner rocker thats on the car to fit IT. Once I get into the damage things can change so I'm hoping there wont be any surprizes...having all the pieces will help in case I need to have a look at something
One of the reasons for seperating the donor chunk is to see how its all put together and what order and where the welds are so when I get to cutting out the original I'll know where everything is and whats connected to it,this way I'll have less chance of screwing something up.

deadbodyman 03-31-2013 07:05 AM

Seperating two pices of steel is fairly EZ but it gets more difficult when you have four and five layers and you want to take each one off seperately. Just looking at pics you dont really get a good idea whats involved and you dont see all the snags that you can run into along the way so heres a vid of me cruzing down the pinch welds which are only two layers and hitting some stubburn welds and multipal layers of thicker structural steel..
Try not to laugh...

deadbodyman 03-31-2013 07:44 AM

having tecnical dificulties ,try again

S10xGN 03-31-2013 10:22 AM

I'm currently back-halving my Rambler American and was facing this dilemma. Drilling spot welds s#cks on the mult-layered stuff, even my plasma rig didn't do as well as a sawzall!


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