Rocker Panel Rust Repair

[csstevej]

So does Raybuck.com.

 

[Steve.VWguy]

Thanks for the info, Any Idea which Brand is best for rockers from Rock Auto? Are these slip on ones cut and weld in place. Interior of remaining Rocker is rusty to so best to replace rather than cover?

 

[HWgeek]

I got mine from raybuck, and finally (about a year later I think) opened up the box. I'm glacial too. State inspection failed so have to fix the rocker now.

Part is NOT primed, but is at least coated with something since it didn't rust in the box. Panel seems fine, if you can find one in pre-primed black, thats the better choice.
(Even though the picture from raybuck shows black, mine was not black)

Front end of the rocker is formed with the fender tab (see pic) so not sure that one needs an "end cap". Guessing there might be someone making an end cap repair part for mild rust repairs.
I'm going to cut out the rust , cut off what I need (at $56, it wasn't worth my time to find a shorter "repair" part). rattle spray primer and all the other stuff.

I have a mig welder that will do the job. Trick is drill small holes in the repair panel where you want to weld to the body (not into the body!!). This makes a "spot" style weld, without having a spot welder.
Have to fix it so, will follow up with some pics and info to share as I work through it.
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[csstevej]

HWgeek, ECS tuning makes those end caps , at least for the golf and Jetta .
I just ordered a left and right and just got them and they look pretty good.

https://c1552172.ssl.cf0.rackcdn.com/910557_x800.jpg

That’s the right ,

Mfg Part #
1J0810222

1J0 810 222
ECS Part #
ES#308536

The left is 1J0810221....... for a couple of bucks each I figured I’d check it out....lol shipping was more than the part.

 

[golfclub]

I am really interested in how you will prep and treat the inside once
the pieces are welded in. My rockers have some surface rust but no
holes yet. Have been wondering how to coat the surfaces inside and out.

Thanks..Peter

 

[HWgeek]

csstevej thanks for the p/n I was looking at ekta but couldn't figure it out.
Got them ordered. went with jimellisvw out of georgia. $5 for the pair + free s/h.
They tend to do well for dealer pricing, fyi. just satisfied customer overall with them.


Golfclub - I start with primering the new part after fitting everything. I use an air flange to make a lip to get a good weld vs doing a butt weld. On the flange area i use weld thru primer, normal on the rest of the part. Also will rattle can spray the part with car paint (masking the welding areas).
Welding will be quick tacks to hold it all together then bead on the outside rocker face and top. Going slowly to not overheat and warp.
Inside coating will likely be undercoating. I have a HF gun that will push the under coating in their. Can always add a tube to the end of the gun to make a cavity probe.
Other options are cavity wax (my concern/opinion is that it "flows" ie it will over years melt out) and fluid film.
Then install the end cap (body epoxy? maybe?) and paint, then also mask and put on under coating in that area under neath and up onto the rocker. Paint over it and clear coat.

At least thats what I think I will do.. Will write up details as I go along for others to fix their vintage vw tdi's!