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  #11  
Old 01-08-2012, 09:32 AM
twotone twotone is offline
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Unhappy heavy Rot

Hello brothers i have bought the steel rectangle six foot 2x4s.And started to cut away the inner rocker on the drivers side and the rust damage is huge.It starts at the front at wheel well and goes to the rear wheel well theres not much left of inner rocker except the top that is good from one end to the other. But the floor pan sides are rotted away.It will need to be rebuilt from there out if possible.I was just wondering if you guys that have already replaced inner rockers started with rebuilding the floor sides and were did you weld the new beam to.Is it the top of the old inner rocker. need some advise as to wear to begin any advise would be appreciated.
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  #12  
Old 01-08-2012, 11:24 AM
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partsetal partsetal is offline
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I haven't used the rectangular tubing but have had a metal shop fabricate 3 lengths of 14 ga, bent so that they could be installed individually and welded in place to resemble the factory box structure with the stiffener strip in the center. With this method, I drilled 1/2" holes in the top surface and then plug welded my structure to it. I haven't had to deal with missing floor support surfaces as mine were still sound. You might consider having some pieces bent that resemble the inner surface angles and place them before you add the tubing.
Bracing of the door opening was important to prevent sag and insure that the doors would fit when the job was finished.
Carl
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  #13  
Old 01-08-2012, 03:41 PM
twotone twotone is offline
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Default inner rockers

Thanks carl for your help i pretty much have to rebuild from the floor wall out torx boxes are still in good shape.so i hope i have somthing to work with thanks again Bro.
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  #14  
Old 01-08-2012, 03:41 PM
lawyercalif lawyercalif is offline
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Good luck on your repair. Having just gone through it here is how we did it. First repair the floors both sides for strength. You can get floor panels cheap on ebay.

Next repair the inner rockers one side at a time and like Partsetal said brace the doors so they do not sag. To install the 2x4 rectangular tubing you must cut away all of the bottom of the old inner rockers. Also you might want to cut away the old inner brace the one with the big holes in if it is too rusty to offer any extra support, this will make more room to get your rectangular tubing in. Cut the rust out of the outer side of the inner rocker saving as much as you can. You have to cut away the part of the bottom of the front fender and part of the bottom of the rear quarter panel to expose the work area.

You then position the tubing into what is left of the old inner rocker and weld it through the top by drilling holes and welding through, welding the sides that are left to the tubing and welding along the bottom flange that should still be intact. Take a close look at the attached pictures, if you have any further questions please let me know. By the way I hope you got tubing that was at least .125 or 1/8" thick.
Attached Images
File Type: jpg Tbird Rebuild 003.JPG (129.6 KB, 661 views)
File Type: jpg Tbird Rebuild 009.JPG (126.3 KB, 659 views)
File Type: jpg 59conv rust 002.JPG (120.6 KB, 659 views)
File Type: jpg rustrepair 003.JPG (113.3 KB, 654 views)
File Type: jpg 003.JPG (112.1 KB, 655 views)
File Type: jpg rustrepair59bird 003.JPG (120.8 KB, 659 views)

Last edited by lawyercalif : 01-08-2012 at 03:51 PM.
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  #15  
Old 01-09-2012, 05:29 AM
twotone twotone is offline
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Wink inner rockers

The steel i bought is .125 thick thanks brother for all your help through all this.
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  #16  
Old 01-09-2012, 12:06 PM
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.125" is MUCH thicker than the steel Ford used and it should work perfectly. Remember to support your floor/body and check for door fitment before you weld. We have had bodies sag so much, the doors wouldn't close. The new channels should straighten this out.

If you think about it, this beam is the end of your torque box, and the beginning of your body rails. If you have metal to replace in the front sub-frame, weld it to your new channel. Space your welds close.

New outer rocker panels will hide the side rails for a finished appearance. - Dave
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  #17  
Old 01-10-2012, 11:55 AM
lawyercalif lawyercalif is offline
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Twotone, please take pictures as you go so you can share the repair with the rest of us.
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  #18  
Old 01-19-2012, 08:02 PM
twotone twotone is offline
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Unhappy

I will brother i have some heavy rot.I removed the steering linkage and found holes were mice got in and had a pillow case full of stuff in the frame.So i have frame work to do.

Last edited by YellowRose : 01-19-2012 at 11:59 PM.
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  #19  
Old 01-22-2012, 01:19 AM
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Lots of rockers in Detroit. Mitch Ryder and Bob Seger just to mention a couple.
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  #20  
Old 04-11-2012, 11:53 AM
lawyercalif lawyercalif is offline
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TwoTone, how is the inner rocker repairs coming? Just curious and wanting to let you know that if you have any questions we are here to help.
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