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ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: impure on November 13, 2006, 11:22:15 AM

Title: rust on rocker panels of new sami
Post by: impure on November 13, 2006, 11:22:15 AM

ok i just picked up my new samurai and it runs good and everything! it has rust behind the plastic guard below the doors. how hared is this to fix? i am going to cut it up today and fix it, anyone encounter this prob? ???

Title: Re: rust on rocker panels of new sami
Post by: lavigeboy27 on November 13, 2006, 01:55:59 PM

yeah, they are all rust buckets. just weld in sheet metal if you can its not to big.

Title: Re: rust on rocker panels of new sami
Post by: impure on November 13, 2006, 07:59:36 PM

well tonight i just cut the holes for new sheetmetal and undercoated the inside of the rocker panels so tomorrow i am going to cut the metal and weld it to the panels! i will take pics of everything tommorow and pics of what the rust looked like. i am planning on painting it within the next three weeks and am going to post the restoration of it here in stages.

Title: Re: rust on rocker panels of new sami
Post by: Rhinoman on November 14, 2006, 04:52:16 AM

If you're taking it off road then why not just cut off the stock sills and go box section

Title: Re: rust on rocker panels of new sami
Post by: lavigeboy27 on November 14, 2006, 06:54:13 AM

Cutting them off is also a good idea, better ground clearance.  All rockers just rot away. Just make sure you don't put the plastic back on, thats what most likely started the problem in the first place.

Title: Re: rust on rocker panels of new sami
Post by: copperzuk on November 17, 2006, 12:09:20 PM

 4x3 square tubeing works very well. You cut the outside off at the lip where the mldg clips, and the inside just up from the bottom.  slip the tube in and weld the sides.  Watch out for wires.  If done right it looks factory and takes a ton of abuse.

Title: Re: rust on rocker panels of new sami
Post by: SKAsammy on November 17, 2006, 12:37:05 PM

i like the idea for the 4x3 square tubing but is there anywhere to get good solid welds on that or do you just weld it back to the body, would it be possible to gusset the tubing to the frame?  I should look into that...