Rocker and Frame Rail, Oh My!

So in this latest installment, we go through the removal of the last bit of the inner side rocker, fixing some more rust cancer and removing that poor excuse for a frame rail.  How that thing ever managed to hold the car up is beyond me.

So first things first.  I separated the last piece of the inner side rocker from the rest of the car.  It was little more challenging than the rest of the piece due to it being sandwiched between the rocker and the torque box.  After some awkward positions and various tools, I had it removed.

I then started stripping back the paint from the myriad holes that were in the rocker from the molding and several rivets.  During this process I found another cancerous area at the back of the rocker.  I cut it out and fixed it the same way that I did with the ones up front.  While I had the welder out I then proceeded to fill in all those pesky holes.  I don't plan on putting the molding back on the car, so I really don't need them.

After that was complete, I stripped away the rest of the paint and proceeded to clean it up.  I then applied a coat of Zero Rust.  It definitely looks much better now.

Next on the list was getting that frame rail out of the car as I have a new one on the way.  It should be here next week.  So I dug into it, wire wheeled all the paint, bondo, seam sealer, rust, and dirt away from the spot welds.  After much drilling, cutting, prying, twisting, hammering and cussing, I finally found all the little areas where it was hanging on and removed it permanently from the car.  On an aside, I finally picked up a Blair Premium Spot Weld Cutter.  This thing cuts like a dream.  If I had been using one of the Harbor Freight ones still, I think I would have already destroyed it.  With any luck this will last me through the rest of the car.  It seems very durable and has taken quite a bit of abuse already.

After looking at the sorry state of the rail, and demolishing another rodent home inside of it, I did a test fit of the new inner side rocker.  It seems to fit almost perfectly, and I shouldn't have to do very much if anything before I weld it in.

Last bit of the inner side rocker removed!

Uh oh, found some more cancer.

Fixed!

Pesky little holes.

Holes are now gone.

Stripped.

Back half.

Boy does that look good.

I think I found them all...but there were some hidden under the floor pan.

Ugly rust at the back.

Eviction notice.  This one was in the shock mount under the transition pan.

It's out!  You can just see the other home in the front of the rail.  Pretty much rotted out that front piece of the rail.  If it wasn't for that, I might have been able to save the torque box.  Problem is, I can't buy just that piece of the rail.  The next problem is that I need the middle section and back section replaced.  Makes more sense to just do the whole thing instead of trying to mess with it.

Cracked almost clean through right at the top of the arch.

I knew this was going to be bad.  Doctor, what's the verdict?  I am afraid the cancer has spread to far.  Our only choice is to amputate.  

It fit really well out of the box.  This should be a piece of cake to install.