1972 Nova Project: Repairing The Rocker Panel

The roof of the 1972 Nova project is finally wrapping up, so I decided to tackle the rocker panel next.  It was rough.  Like… really rough.  The outer rocker panel was missing, along with the lower fender mount and the inner bracing that keeps everything structurally sound. Repairing it was not the easiest thing that I have ever done.

The first step was to cut away all of the rotted metal until you find a solid base to work with.  Then, since nobody makes replacement metal for this area, I had to fabricate my own.  I started with the inner bracing since that was the deepest part.  This piece was more complicated than I expected, because it is actually the lowest portion of the inner kick panel.  (Think about that for a moment.)  That interior kick panel metal goes down through the floor pan, and into the rocker where all of these different pieces meet up in harmony.  To get the rusty section out, I had to cut a section out of the newly replaced interior floor pan, along with all the metal on the outside.  Once I had it out, I grabbed some flat metal and started fabricating the piece that I needed.    Since nobody likes reading, here is the story in the form of pictures.  Enjoy, and leave some comments so that I know somebody is here besides me.