Single Cab Rocker Replacement

Pix by Tom Mink

Replacing a rocker on a single cab is only slightly different than doing one on a normal bus. The main differences

Different views of the rusty rocker.

Remove the outer rocker. Make a cut just inside the seal channel all the way across, and then down - stop the cut about 1" short of the seam. Then dill out the spot welds holding the center piece to the end piece. In this particular case, the rocker was rotten enough that it just popped off by itself.

Here I cut away more of the ragged metal to make it easier to work in the area.

Note the two layers of metal: the outer one is what is called the inner strengthener; the inner piece is the inner rocker. Some replacement panels will come with the inner strengthener already welded to the outer rocker, some won't. Alan Shofield's don't, Wolfsburg West's do.

Next cut away the inner strengthener. Make a cut thru the inner strengthener, then pop the first spot weld on one end with a chisel, and you'll be able to pull down with a pair of vice grips, popping each spot weld by pulling down and twisting. If a spot weld won't pop, hit it with the chisel.

With the inner strengthener gone, start on the inner rocker. You'll have to air-chisel it off of the floor I-beam, as well as off of the cargo floor. Take care not to cut thru the cargo floor!

We made the decision to keep the original short rocker piece, but removed it to facilitate removing the inner rocker.

The front section won't be as easy. Just dig in with the chisel and get that rusty metal cut out!

Inner rocker welded to the I-beams

Outer rocker (with strengthener built-in) fitted to the body. Notice the overlap over the original metal in the front - that is the correct fitment.

Short rocker tacked back on, with the new outer rocker fitted over it.

Outter rocker welded in.

Finished off and primed, awaiting finish bodywork and eventually, paint.
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