Rust is the nemesis of every car owner. It can cause unsightly blemishes on the exterior, and if left unchecked, it can lead to structural damage and costly repairs. Rocker panels, located on the lower part of the car’s body, are particularly susceptible to rust due to their exposure to road debris, moisture, and salt. However, DIYers can effectively fix rusted rocker panels without breaking the bank by following these steps.
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Understanding Rocker Panels and Rust
Rocker panels, sometimes called pinch welds, are structural components that run along the sides of the car, connecting the floor pan to the body. They provide structural support, protect the car from road debris, and help to create a more aerodynamic shape.
Rust forms when iron or steel is exposed to oxygen and moisture. In the case of rocker panels, rust is often caused by moisture trapped between the rocker panel and the undercoating. Salt and road debris further accelerate the rusting process.
Assessing the Damage
Before attempting any repairs, it’s crucial to assess the extent of the damage. Examine the rocker panels underneath the car. If the rust is only on the surface, it’s likely a minor issue that can be fixed with minimal effort. However, if the rust has penetrated deeply into the metal, more extensive repairs may be necessary.
Preparing the Repair Area
Once the damage has been assessed, it’s essential to prepare the repair area. Remove any loose paint, rust, or debris from the surface of the rocker panel. Wear gloves and protective eyewear during this process. Use a wire brush, grinder, or sanding disc attached to a drill to remove the rust down to bare metal.
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Cutting Out the Rusted Section
If the rust has penetrated deeply into the metal, you may need to cut out the damaged section and replace it with a new piece of metal. Use a metal saw or angle grinder to make a clean cut. Be careful not to damage any surrounding parts of the car.
Fitting a Replacement Panel
If you’ve cut out a rusted section, you’ll need to fashion a new piece of metal to replace it. Use a sheet metal cutter to cut a piece of metal to the correct size and shape. Weld the new piece of metal in place, ensuring a secure and airtight connection.
Applying Seam Sealer
Once the replacement panel is welded in place, it’s crucial to apply seam sealer to the joint. Seam sealer is a flexible adhesive that helps to prevent moisture from getting into the seam between the two pieces of metal. Apply a generous amount of seam sealer to the joint and smooth it out with a plastic tool.
Priming and Painting
To protect the newly repaired rocker panel, prime the repaired area and then apply a coat of paint. Use a spray gun or brush to apply a high-quality primer. Once the primer has dried, apply a matching coat of paint to the repaired area.
Preventing Future Rust
To prevent future rust from forming on the rocker panels, it’s a good idea to take a few preventative measures. Apply undercoating to the underside of the car, including the rocker panels. This will help to protect the metal from moisture and road debris. Additionally, regularly wash your car to remove salt and other corrosive substances that can damage the metal.
How To Fix Rusted Rocker Panels Cheap
Conclusion
Fixing rusted rocker panels can be a daunting task, but it’s one that most DIYers can accomplish with the right tools and materials. By carefully following the steps outlined in this guide, you can restore the structural integrity and aesthetics of your car without paying a hefty price tag. Remember to prioritize the thorough preparation and protection of the repair area to ensure long-lasting results and prevent future rust problems.
