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Wrecked Rocker Repair

Autowerks Saves the Day!
By Mike Finnegan
Isuzu Pickup Front Drivers Side View
Isuzu Pickup Front Passengers Side View
1. This Isuzu only laid frame... 
   
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Isuzu Pickup Front Passengers Side View
1. This Isuzu only laid frame when it encountered a bump in the road that wrecked its passenger-side rocker panel. Once it has been body-dropped, the owner will either have to be more careful when he drags or be continually repairing the damage.
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2. After cutting the bottom... 
   
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2. After cutting the bottom of the old rocker panels off with a reciprocating saw, new panels were bent out of 1/8-inch cold-rolled steel.
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3. The new rockers will be... 
   
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3. The new rockers will be welded directly over the outer edge of the original rockers. This truck is in the middle of having its cab body-dropped, so the inside edge of the rockers will be attached to the filler panels for the cab floor. On Isuzus, the rocker panels do not sit flush with the lower portion of the door skin, and this makes it easy to blend the new rocker panels into the old ones.
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4. To make sure the new rockers... 
   
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4. To make sure the new rockers will line up with the door, a tape measure and level are used.
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5. Once the new rockers are... 
   
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5. Once the new rockers are lined up with the upper edge of the old rockers, they are clamped in place in preparation for welding.
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6. Jimmy welds along the upper... 
   
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6. Jimmy welds along the upper edge of the rocker, moving from one end of the panel to the other in an effort to keep the metal from getting too hot and warping.
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7. It takes some time, but... 
   
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7. It takes some time, but eventually the entire panel is spot-welded to the cab with zero warpage.
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8. A 4-inch angle grinder... 
   
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8. A 4-inch angle grinder is used to grind all the welds smooth and flush with the sheetmetal. If done properly, a minimal amount of body filler will be needed to make everything look like it came from the factory.
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9. The mud is liberally applied... 
   
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9. The mud is liberally applied to both the new rocker panel and the inside of the doorjamb.
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10. After sanding down all... 
   
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10. After sanding down all of the body filler, the rockers are coated with epoxy primer.
Isuzu Pickup Drivers Side Body Drop View
11. In addition to the new... 
   
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Isuzu Pickup Drivers Side Body Drop View
11. In addition to the new rocker panels, this truck also received a 3.5-inch body drop from Autowerks. This is good timing because the new rockers will most assuredly handle the abuse doled out by the owner of this mini better than the stock ones.

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