MODULE 2ROCKER PANELS

Topic A. Rocker Panel Designs And

General Sectioning

A-3 When using general guidelines to determine the sectioning location,

consider how the rocker panel is assembled by the OEM.

A-2 Rocker panels may have a variety of assembly methods.

Rocker panels are located on uniside and multi-part

constructions. Designs of rocker panels include:

two-part. Two-part rocker panels have an inner

and an outer panel. The inner panel may or may
not be part of the floor pan.
three-part. Three-part rocker panels have an inner panel, outer panel, and reinforcement.
multi-part. Multi-part rocker panels have an inner
panel, outer panel, and multiple reinforcements.
Multiple reinforcements make it more difficult to
use inserts.

When considering the location of cut lines, use

general sectioning guidelines, such as keeping joints:

in the center of door openings.

away from the base of pillars. These areas typically contain multiple reinforcements.
away from laser welds. Laser welding uses a highenergy light beam to melt the top panel through
to the surface of the bottom panel. This process
does not use a filler material to weld the two
pieces together.
away from restraint mounting locations.
between OEM spot welds.

Rocker panels are considered high abrasion areas

where the use of plastic filler should be minimal.

ROCKER PANEL DESIGNS

Select the Demonstration Icon found on screen
A-2 of your CD-ROM for examples of rocker
panel designs.

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2001 Inter-Industry Conference On Auto Collision Repair

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Topic B. Rocker Panel Repair

Procedure

A-4 Determine how adjacent parts are routed around and through the
rocker panel before starting the repair procedure.

It may be necessary to remove adjacent parts from

the repair area before performing repairs to the
rocker panel. Parts that may need to be removed
include:

interior trim, such as the carpeting, front and rear

seats, weatherstripping, and pillar and door trim.
exterior trim, such as cladding.
doors.
the fender.
the quarter panel.
computers and wiring.
fuel and brake lines that are routed through or
around the rocker panel.
Check for fuel and brake lines, electrical parts,
foam filler, etc. before cutting or welding.

Structural Parts Steel Program 2 v.3.1Module 2

2001 Inter-Industry Conference On Auto Collision Repair

B-1 Many types of equipment can be used to measure the dimensions

of a vehicle, including a computerized measuring system such as this.

Before removing the damaged rocker panel, prepare

the vehicle by:

restoring under and upperbody dimensions. This

is accomplished by using pulling equipment to
straighten the vehicle to the proper dimensions.
checking panel alignment and door operation, if
possible.
installing necessary supports. The rocker panel
supports the pillars and the floor. Once removed,
the structural rigidity of the vehicle will be greatly
decreased. Support the vehicle to prevent it from
collapsing.

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B-3 The initial cut may also be called a rough cut. The final cut is the
sectioning joint location.
B-2 The replacement part should be examined for damage and verified
as soon as possible so that new parts can be ordered, if necessary. The
replacement part should be positively identified before partial or full
replacement operations begin.

When making initial cuts on the outer rocker panel:

When planning to remove the outer rocker panel:

verify that the replacement rocker panel is correct by checking part numbers and comparing
the replacement to the vehicle and the original
rocker panel. Inspect the service part for the
number and location of welds, weld spacing,
multiple layered seams, brackets, mounting holes,
and overall part configurations. This step is important because the service part welds may have
been omitted or pieces may only be tack welded
in place for shipping and part location purposes.
locate the seams and spot weld locations.
identify type, location, size, and number of replacement welds according to the repair
procedure.
plan cut lines.

cut the rocker panel long enough to allow for

trimming to size.
provide clearance by removing the spot welds
and separating the outer from the inner rocker
panel. Use caution not to damage the flanges,
inner rocker panel, or reinforcements.

B-4 Spot welds in the initial cut location are removed before the initial
cut is made. The rest of the spot welds that attach the outer rocker panel
to the reinforcements and inner rocker panel are removed after the initial
cut has been made.

After making initial cuts, remove:

Structural Parts Steel Program 2 v.3.1Module 2

2001 Inter-Industry Conference On Auto Collision Repair

any additional spot welds.

the damaged rocker panel.
foam filler, if necessary.
adhesives, if necessary.

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B-5 The inner and outer rocker may not show signs of an excessively
corroded reinforcement.

When planning the repair for an inner rocker panel:

examine the condition of the inner rocker panel

and all reinforcements.
repair or replace any damage that is identified.
Some vehicle makers do not recommend sectioning inner rocker panels or reinforcements.
replace the inner rocker panel or reinforcements
because of excessive corrosion.

B-7 A template may be used to identify the cut lines.

When preparing for replacement rocker panel

installation:

take measurements at reference points that are

common to the vehicle and the replacement
rocker panel. Mark the cut line location. Cut the
rocker panel to fit to specifications.
trial-fit the rocker panel.
straighten any damage to the flanges.
punch or drill plug weld holes, including holes
that may be used for an insert or long lap joint.
remove the E-coat. Do not remove the zinc
coating.
corrosion protect the backside of the panel, if
necessary.

B-6 Additional interior parts may need to be removed to access the inner
rocker panel. Supports may need to be removed and reinstalled to gain access.

When removing the inner rocker panel:

remove the plug welds.

initially cut the rocker panel longer than needed
in preparation for final cutting and fit-up.
do not damage the flanges or any additional
undamaged reinforcements.

Structural Parts Steel Program 2 v.3.1Module 2

2001 Inter-Industry Conference On Auto Collision Repair

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B-9 Verify that the root gap or overlap is correct.

B-8 Once the final cut line has been made on the replacement rocker
panel, it can be used as a template for the final cut line on the original
rocker panel. Remember to protect the area when making the final cut.

When test-fitting the replacement rocker panel:

When preparing the original rocker panel for replacement:

verify the rocker panel fit-up.

final cut it to the proper gap or overlap.
straighten and remove all of the burrs and spot
weld nuggets from the mating flanges and joint
areas.
remove the paint coatings. Do not remove the
zinc coating.
corrosion protect the backside of the panel, if
necessary.
properly create and install an insert, if necessary.

Structural Parts Steel Program 2 v.3.1Module 2

2001 Inter-Industry Conference On Auto Collision Repair

position the rocker panel using clamps or screws.

Screw holes must be welded closed after the part
has been welded into place.
allow the weight of the vehicle to rest on the
suspension. Then verify the dimensions and panel fit.
trim the rocker panels to the proper gap or
overlap, if necessary.

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B-11 Control the heat-affect area by using the stitch weld method.

Steps that should be followed when welding the

rocker panel include:

B-10 If screws are used to hold the rocker panel during fit-up, the screw
holes must be welded closed during welding operations.

When preparing the area for welding:

apply weld-through primer to bare metal surfaces in the weld area. Weld-through primer may
be removed from the weld zone to reduce cold
start, spatter, and increase weld quality, while
still providing corrosion resistance to the area.
apply necessary adhesives.
reposition the replacement rocker panel using
clamps or the screws used earlier and verify the
measurements.
protect the vehicle.

1. Perform test welds on scrap pieces of rocker

panel that are the same type and thickness as the
vehicle.
2. Tack weld or finish plug welding the insert.
3. Verify measurements.
4. Make required welds. The stitch weld method is
used to control the heat-affected area.
5. Verify measurements.
6. Perform a visual inspection.
Personal protection when welding includes:

Structural Parts Steel Program 2 v.3.1Module 2

2001 Inter-Industry Conference On Auto Collision Repair

wearing a welding helmet with a filter lens.

wearing safety glasses, protective gloves,
and protective clothing.
wearing a welding respirator.
not having matches or butane lighters in
pockets.
making sure clothing and shoes are free
of oil, grease, or other flammable
materials.

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Any electrical welding process produces electromagnetic fields and heat, which can damage sensitive electronic parts. Precautions to
take whenever using any type of electrical
welding process include:

removing computer modules when welding close to them. The general recommendation is to remove the modules if
welding within 300 mm (12") of these
modules. Temporarily store the modules
in static bags.
disconnecting and isolating battery cables,
especially the negative battery cable.
Remove the battery if it is in the immediate area to be welded.
recording and resetting electronic memories. Not all electronic memories can be
electronically captured and need to be
manually recorded or obtained from the
vehicle owner.
disarming the passive restraint system.

B-12 Remember to apply corrosion protection to the underside of the

vehicle.

To complete exterior rocker panel installation:

Cover all other areas adjacent to the repair

area with welding blankets.

Structural Parts Steel Program 2 v.3.1Module 2

2001 Inter-Industry Conference On Auto Collision Repair

dress the welds. Do not grind into the base metal

when dressing welds, because it reduces the
welds strength.
replace necessary foam filler.
corrosion protect the exterior. Follow paint
makers recommendations for types and methods of exterior rocker panel corrosion protection. Typically, an epoxy or self-etching primer is
recommended for exterior surfaces before applying topcoats.
apply corrosion protection materials to the inside of the rocker panel through an access hole.
Wax-based corrosion protection compounds are
applied after repairs and refinishing operations.
This type of corrosion protection stays soft unlike
foam filler material. Typically, an epoxy or selfetching primer with an anti-corrosion compound
is recommended for the inside of an enclosed
part.

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When applying corrosion protection, make

sure to wear:

a NIOSH-approved vapor air-purifying

respirator or a supplied-air system.
protective clothing.
rubber gloves.
a face shield or safety glasses.

Spray in a well-ventilated area, away from

welding operations and open flames.

When dressing welds, do not thin adjacent

metal.

B-14 Use a film thickness gauge to verify that the correct amount of
refinishing material has been applied.

After repairs have been made, inspect the repair area for:

proper dimensions.
weld quality.
film thickness and finish appearance. Verify that
all rock guard protection has been installed.
corrosion protection application.
panel alignment.
label replacement.

Topic C. Rocker Panel Sectioning

B-13 Duplicate the type and appearance of the OEM seam sealer
application.

SECTIONING A ROCKER PANEL

Refer to screen C-1v of your CD-ROM for a
video on sectioning a rocker panel.

To complete the repair:

use necessary seam sealer applications.

apply topcoats.
install additional related panels and parts.

SECTIONING THE CARDBOARD ROCKER

PANEL
Select the Activity Icon on screen C-2 of your
CD-ROM for an interactive activity on how to
section the cardboard rocker panel.

Topic D. Review
REVIEW
Refer to screens D-1 through D-2 of your
CD-ROM for review questions on rocker
panels.
Structural Parts Steel Program 2 v.3.1Module 2
2001 Inter-Industry Conference On Auto Collision Repair

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