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Help me do this HACK job


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bradleyheathhays
New User
bradleyheathhays profile image

Sep 29, 2022, 10:23 PM

Post #1 of 6 (736 views)
Help me do this HACK job Sign In

So I've got a decent looking survivor jeep and the only obvious body problem it has is the driver side rocker panel.
The panel itself is rusted through and although the overall plan is to completely replace it, for now I just need to fill

in the hole and keep it from being what draws your eye. Doesn't have to look good at all, just filled and red would make

me happy.
Although it's a little hard to make out the panel is fairly solid other than where it's rusted out. I'll end up removing
anything that's thin and go from there. My best idea is to get some kind of back support (wire sheet or whatever)
and insert it into the hole and secure it with some kind of adhesive/epoxy. After clearing out the rusted metal, this
support piece I'm imagining would be about 18" long x ~5" tall with a break down the long dimension for where the
bottom of the rocker panel bends under. If I get it to the point where I have a backer panel secured I have just
enough experience to build up the bondo, sand, prime and paint without any much more advice.

2 questions...what kind of supporting (metal?) sheet am I looking for? and

what kind of adhesive/epoxy should I use inside the rocker panel to secure the backing sheet?

Also, any general advice on securing this support panel with adhesive would be appreciated. Thanks.

(sorry for the big a## picture)

Picture deleted


(This post was edited by Hammer Time on Oct 1, 2022, 6:49 PM)


Tom Greenleaf
Ultimate Carjunky / Moderator
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Sep 29, 2022, 11:24 PM

Post #2 of 6 (720 views)
Re: Help me do this HACK job Sign In

Try to shrink down that pic.
HACKING - your word I get it.
Just wire brush of loose yuk, a larger hole will
be there use maybe aluminum tape as a base for
a Bondo, some has hair in it bridges gaps.

What model is this some these panels matter if not a chassis Jeep.
BTW Google out places that sell aftermarket panels or parts of metal parts a common rocker panel to do right is a real PITA, spot welded in place don't drain water/muck out well.

Frame strength if a Wrangler (the CJ type underside vs unit body is going to matter so say so.

It will all come back you merely buy some time (not too long) before you see it again until all rust unseen is cut out.

Not my trade will do thoughtful but safe hacks + make them look OK on body parts that don't harm anything - U need to know that so do I to suggest more.

In general rusted there it's worse somewhere else check whole vehicle for an area that might be way too far gone,

T



Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Oct 1, 2022, 6:51 PM

Post #3 of 6 (696 views)
Re: Help me do this HACK job Sign In

I had to delete your picture. It was WAY too big. The site software makes it real easy to reduce the size. Bring it down to at least 1/4 of the original size.

Unless you completely cut out every scrap of rust, it will be back before the paint even dries.



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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Oct 1, 2022, 7:03 PM

Post #4 of 6 (690 views)
Re: Help me do this HACK job Sign In

So right. The hack is like duct tape over it, the problem is chronic behind it you don't win without 100% removal as Hammer said, T


bradleyheathhays
New User
bradleyheathhays profile image

Oct 27, 2022, 10:21 PM

Post #5 of 6 (438 views)
Re: Help me do this HACK job Sign In

Thanks for all the advice. I decided to do it the hard way and rivited in 1/8" diamond plate aluminum for support and now I've just applied my second good layer of bondo. I'm gonna end up with more than the 1/8" recommended max bondo depth, probably around 1/2" in places, but I figure that's not a surprise.
So now I need to know...how I build up and go from the craggy bondo section on the right to a paint ready rocker panel shaped section like on the left.



Pictures deleted ............. too large


(This post was edited by Hammer Time on Oct 28, 2022, 3:52 AM)


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Oct 28, 2022, 3:54 AM

Post #6 of 6 (419 views)
Re: Help me do this HACK job Sign In

Again I had to delete your pictures because they were WAY too large.

You have to realize that anything over 1/8 inch of filler will soon crack and fall off.



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.







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