Yup....inner rocker rot....

[Obscurity]

Hokay....now that I've said I'm back, the questions start I'm trying to decide how to tackle the inner rockers before I finish with the exhaust....just so I'm ready.....

Problem: Inner rockes have some rot....as in holes resembling fine Victorian lace, but with less structural integrity. (not quite that bad but close....I'll try to get some pics as soon as I can convince myself to go lay in the snow to take them). I haven't pulled the carpet for quite a while, but I think it isn't TOO awful under there...perhaps a teensy bit soft in spots, but no holes. We need to use the Eagle this winter to get around. It has to pass inspection, I think the guys I go to are...um.....not dishonest, but will let some things slide....though the rockers are too much I'm guessing. I want to get the car undercoated to slow down any rust spots we can't get to, or don't know about just yet so the car will last through the salt and snow without falling apart by January. We are also on a really tight budget (yeah.....) and neither hubby or I can weld (yet), we do have a couple of friends who know how, but I don't know how skilled they are.

What I'm looking for: cheapest, quickest, easiest solution to get those rockers through the winter, and preferably not cause 10x more work if something more extreme needs to be done down the road, can't handle a temp fix that will do irreparable damage in the long run.(not asking much am I lol.....). I know that the worthwhile options will require welding....but the lower the welding skill required the better!

So.....options I'm looking at so far....and yes, I'm reaching: Metal patch, could be some awkward cutting, but doable (what thickness is best?. Box steel and just cut the darn thing outta there and weld a new one in (I kind of like the structural bonus of this...was considering it for a while). Or, cross my fingers, hope it passes and if it does just undercoat and pray (won't work will it lol). Someone suggested bondo just to get through the winter (or until a cash windfall, whichever comes first), but I'm really reluctant to go that route. The temperature doesn't help that option either.

I had one suggestion, that I'm only going to share because it gave me a good giggle: Spray rust check, then use the holes to fill the inner rocker with monofoam and cover it with rubber-rock guard. Gotta say, as unlikely as that is to be kosher....the simplicity is almost attractive lol.

Anyway, considering what I'm looking for/need for this repair....what is your thoughts on the easiest AND most cost effective way to go that won't cause problems for me.I'll try to get some pictures a little later today and add them in. I've got a heck of a cold going on, and I stayed home from work because of it....gotta bundle up and not get caught 

[Draekon]

Filling the rockers with foam would make it very difficult to fix properly later on.  I would stay away from that option.  If you can get it to pass inspection, I would just get some subframe connectors built and welded in.  That should restore the structural integrity, while not destroying what may be left of your rockers.

[Obscurity]

Yeah, I wouldn't do the foam thing....just thought I'd share that one for the giggle it gave me (I mean if this was a "beater with a heater" for the winter, it wouldn't be a bad idea....but not on my Beast.

The subframe connector idea is interesting for the structural integrity, something I may do either way if it proves to be inexpensive enough...but, if I understand correctly, that'll leave the rockers still exposed (and visible). Two problems there. First, if I'm right for the rule of thumb for inspecting here....if there is a rust hole anywhere, it won't pass (I've also heard hole the size of a dime....). Not sure if that includes the underbody....but it probably does. Secondly...would some rust-check and/or undercoating preserve the inner rockers for the duration.....the salt here is REALLY nasty. I've got the unfortunate situation of having to try to fight the salt, and the price/logistics of the rockers being fixed even if I could sneak them through inspection.....or are you suggesting perhaps toss some bondo on there to basically "plug the holes" along with the connectors?.

[Obscurity]

Ok.....got some pics, you'll have to excuse the awful angle, but there's a big puddle right next to the car, too lazy right now to lay in that lol... so reached under and went blind.....

From front to rear driver's side, didn't overlap very well, but should give a good idea of the state of it. Its pretty bad, especially at the rear, where, now looking again, it seems inner rocker is only part of the problem....
   


   

[1985amceagle]

I am also against the filling the rocker idea with foam, my car has had that done. while it keeps the dust out of the cabin, it seems to hold water better and never seems to dry out, I assume the what else is left of the rocker is going to rot out a lot sooner as well.

[Obscurity]

Oh no!! Someone actually did that to an Eagle!! A beater with a heater is one thing....but yuck......I guess I was right that it would do more damage than good then. Well....tarnished silver lining is that at least it keeps dust out

[Mernsy]

You can always advertise for a body man on Kijiji. Lots of folks looking for extra cash for Christmas and New Years.

[Obscurity]

Good idea Mernsy!! Once the muffler is on, if the few connections I have aren't up to the job I'll do that! Actually there is a guy on Kijiji that is advertising welding lessons...(cheap too!!!) if I had the time to spare I'd take welding lessons from the guy and learn to do it myself. I might even try calling that guy and asking if he can do it...fully ticketed, so that's a bonus (not autobody....but he has likely had experience). I will probably do the lessons down the road, but need to get this rolling soon.

[Whuntmore]

That's quite a bit of rot!!  I rebuilt my inner and outer rockers, but mine had pin holes where the two meet - Not straight out severe rot.

from what I can see of the pictures, it's not just the rockers, but some of the supports and floor as well...

[1985amceagle]

Oh no!! Someone actually did that to an Eagle!! A beater with a heater is one thing....but yuck......I guess I was right that it would do more damage than good then. Well....tarnished silver lining is that at least it keeps dust out

the plastic that covers the rocker panels seemed to do more harm than good. I believe that the flares trap moisture, and road debris in between it and the flare, and cause it to rust out.

[Whuntmore]

Oh no!! Someone actually did that to an Eagle!! A beater with a heater is one thing....but yuck......I guess I was right that it would do more damage than good then. Well....tarnished silver lining is that at least it keeps dust out

the plastic that covers the rocker panels seemed to do more harm than good. I believe that the flares trap moisture, and road debris in between it and the flare, and cause it to rust out.

For sure.  I took mine off as soon as I got the car.  Nothing but trouble.

[Obscurity]

Yeah, I'm a little scared of what I will find when I remove those outer covers. I'm expecting it to be pretty bad. And yes....its looking like some floor supports are toast. This is going to be much more expensive (and more time consuming) than I had hoped I think......still not sure what to do

[Obscurity]

Ok, I've got a line on a guy, but I need some input.
The guy worked in the past at a body shop, did a great deal of body welding. Not ticketed, but experienced. He now works in a granite shop, and my hubby knows his work, and knows he is meticulous and takes pride in his work (yeah, I know granite and metal are different, but it says a lot to his work ethic). I'm not sure if we'll be using his welder or not, because he doesn't have a garage right now. We have a friend with a garage and a welder (the welder guy and the garage/welding machine guy are friends and neighbors).

So....I need some suggestions on $$$
Need to pay:
Welder for his labor/skills
Friend for garage time (he would let us use it for free....but I know they could use some cash)
Friend for use of his welding machine (he just wants materials and a couple bucks for power)
Also a guesstimate on materials cost would be awesome (though the welder has materials he'll probably donate to the cause....so I do want to be sure to toss him appropriate cash for this).

Keep in mind, we will likely also be funding some beer and pizza during the process, as well as helping with the non-welding labor (I'll get the carpets out, etc). Only problem I foresee with the guy is he is a bit of a chatter......we'll have to put in some work to keep him on track lol. He is quite a character and the worst thing I've heard from people, when I've mentioned him perhaps doing the work is "it would be great if you could get him to stop talking for long enough....otherwise it'll take weeks". So yeah....not paying him by the hour.

I honestly have no idea what is appropriate cost for this kind of project and I don't want to take advantage of anybody, nor do I want to get ripped off....Thoughts and input anybody?

[Mernsy]

Ballpark estimate...No more than $500. $200 per side and $100 for your neighbour. (Try to get an estimate from the welder before he starts.) Sheet metal is cheap. Grab an old stove or refrigerator.

[Obscurity]

Sounds like the ballpark I was thinking and hoping for. Hubby and I were hoping/thinking the welder might ask for 300ish, and we can't really afford to go much more than 500 total anyway. Glad we were about right in what we were thinking. If he "hmmmms and haaaas" about a price when we ask we'll suggest 300 and he'll probably take it (if we whined enough he'd probably do it for less....but don't want to burn that favor). Chances are his sheet metal is old appliances, and if that's the case he'll probably consider it covered by pizza and beer