My build *UPDATE* 8/11/18

[SmashingPunkFan]

Found some rocker panel rust through... any suggestions? Definitely aiming to patch rather than replace.
What gauge steel should I use?

The inside of the rocker/rail thats rusty seems extremely rusted inside.
Any suggestions on how to clean, or prevent future rust progression?

[SmashingPunkFan]

Found some rocker panel rust through... any suggestions? Definitely aiming to patch rather than replace.
What gauge steel should I use?

The inside of the rocker/rail thats rusty seems extremely rusted inside.
Any suggestions on how to clean, or prevent future rust progression?

The original inner rocker panel appears to be 22 gauge steel. I'm using rear quarter replacement donor patches to replace. So its now 20 gauge. Should hold up nicely

[SmashingPunkFan]

A little more progress

[SmashingPunkFan]

 Its all done!



https://youtu.be/L-olG1tm_vA

[PlainfieldCharger]

  Great video! Really gives you motivation

[Bronzedodge]

Looks good!

[SmashingPunkFan]

Moving forward to the quarters now...
Does anyone by chance have a decent shape passenger side one of these end caps they could part with?

Thanks for the info!

[SmashingPunkFan]

So, I was working on some stuff and this fell off tonight...

[SmashingPunkFan]

Working on this, and any advice on fitment?

[green69rt]

I see a picture, of what looks like the seat supports that go under the floor.  You probably already know that the supports are not all the same.  They're the same left to right but not front to back.  They look the same but they are not.  Wish I could explain better.

[SmashingPunkFan]

I see a picture, of what looks like the seat supports that go under the floor.  You probably already know that the supports are not all the same.  They're the same left to right but not front to back.  They look the same but they are not.  Wish I could explain better.

Oh dang, I totally forgot to mention what it was. Sorry!
Its the rear end of the quarter where it meets the tail light panel. I have good fitment on the othet end where the quarter mates to the door jam pillar. But here it appears to be a bit too long, and I was wondering if there was a trick or something to make it work better.

I really appreciate the help and advice

[hemi-hampton]

If the replacement 1/4 is aftermarket then it probably is to long.

[hemi-hampton]

Trick I use is put that end on first. then dont go all the way into the door jamb but weld the 1/4 about 1 inch before it goes inside door jamb & stays on outside. Why, this way it still retains the factory look & factory welds inside the door jamb. I use a panel flanger. Just my opinion. I'm sure others will disagree. LEON.

[SmashingPunkFan]

Trick I use is put that end on first. then dont go all the way into the door jamb but weld the 1/4 about 1 inch before it goes inside door jamb & stays on outside. Why, this way it still retains the factory look & factory welds inside the door jamb. I use a panel flanger. Just my opinion. I'm sure others will disagree. LEON.

That sounds like a good idea, I'm gonna play with it some as well. I know the rear end has had some side impacts before, hopefully it didn't push the tail panel in too far

[hemi-hampton]

Sample pic from 17 years ago when full 1/4's were not available. LEON.

[SmashingPunkFan]

Sample pic from 17 years ago when full 1/4's were not available. LEON.

Wow, a step back in time. That looks awesome Leon!
The only trouble with that method is, I had already cut away everything below the top body line including the door jam factory welds.

I trimmed a crossway between the new quarter and existing top line of the old quarter,  and I can now get it to slide with plenty of room forward from the tail light panel, but it pulls away from the door jam pillar...  

[hemi-hampton]

Notice I like to weld my 1/4's while on the ground on it's tires sitting on it's own weight. You get to much flex otherwise. Unless you have frame tied with sub frame connectors. I've seen many gaps screwed up not doing it this way. I like my gaps perfect. some peoples gaps suck. Good Luck. LEON.

[SmashingPunkFan]

Notice I like to weld my 1/4's while on the ground on it's tires sitting on it's own weight. You get to much flex otherwise. Unless you have frame tied with sub frame connectors. I've seen many gaps screwed up not doing it this way. I like my gaps perfect. some peoples gaps suck. Good Luck. LEON.

Ahh, that isn't something I've thought of before. I have the front on coasters, and the rear axle on stands. It seemed like a "simulated" weight.  Maybe it's not accurate enough though.

[lukedukem]

In your video, at the 2 min. mark, what is that black stuff your putting down in the channel of the cross members support

Luke

[SmashingPunkFan]

In your video, at the 2 min. mark, what is that black stuff your putting down in the channel of the cross members support

Luke

POR-15 rust incapsulator. I love that stuff, just keep it away from heat and sunshine. 

[SmashingPunkFan]

Here is my current dilemma.
I have some significant rust between the drivers door and wheelwell on the rocker panel area... very solid, but pitted.
I don't know exactly how to seal this, or neutralize the rust before I weld in the new quarter because I won't  be able to get to it after the heat cools down for por-15.

Need some 
Thank you

[SmashingPunkFan]

Pics of problem

[SmashingPunkFan]

Some progress...

[green69rt]

Here is my current dilemma.
I have some significant rust between the drivers door and wheelwell on the rocker panel area... very solid, but pitted.
I don't know exactly how to seal this, or neutralize the rust before I weld in the new quarter because I won't  be able to get to it after the heat cools down for por-15.

Need some 
Thank you

After you are done welding, you could try eastwoods Internal frame coating.  You can get into some tiny places with the spray tube they give you.  Just be ready for the cleanup afterward, it's extremely runny and goes everywhere.  Cleans up with degreaser if you don't let it set for more than a couple of hours.

http://www.eastwood.com/eastwood-internal-frame-coating-14oz-aerosol.html

[SmashingPunkFan]

Here is my current dilemma.
I have some significant rust between the drivers door and wheelwell on the rocker panel area... very solid, but pitted.
I don't know exactly how to seal this, or neutralize the rust before I weld in the new quarter because I won't  be able to get to it after the heat cools down for por-15.

Need some 
Thank you

After you are done welding, you could try eastwoods Internal frame coating.  You can get into some tiny places with the spray tube they give you.  Just be ready for the cleanup afterward, it's extremely runny and goes everywhere.  Cleans up with degreaser if you don't let it set for more than a couple of hours.

http://www.eastwood.com/eastwood-internal-frame-coating-14oz-aerosol.html

Is it a pretty solid product? I shall give it a try.
Thank you for the info