My DIY Weld Free Rocker Panel Rust Repair 

Nice repair! Here are some suggestions for future repairs from my experience: 1. A tip i'd suggest is using fiberglass itself for the repair, I believe it would be much easier to get the shape back using it. Besides, from what I've heard fiberglass holds on to metal stronger compared to fillers. You can find a great youtube video covering using my mentioned by 4diyers, I like his method a lot, and used it for repairing a rust hole in my car's wheel arch. 2. I believe that a rust converter is a great idea in the front of the repair too, since from what I've observed it's unlikely that you'll take all of the rust off - some of it will stay in the pitting, and might come back if left untreated. If you decide on using it, just make sure to not sand through it, it needs to stay undamaged. 3. I don't recommend using a wirewheel attachment for removing rust - I've observed that it polishes some of it, and it looks like clean metal, when in reality sometimes if you'd hit the spot with a hammer you'd find that a chunk of rust would fall off. I'd suggest using a sanding attachment instead, that way you won't be doing any rust polishing :) 4. About the rubberized undercoating: I'm not sure if I'd want to use it, and I have not used it on any of my repairs. The reason is that unless it's applied over clean painted metal (rust converters need a top coat usually, the rubberized undercoating might not be a good substitute for paint), they trap moisture and accelerate rust, there are multiple youtube videos talking about this issue. I am by no means a professional, it's just something I've gathered from reading countless forums, and watching youtube videos. Good luck on your future repairs, you'll get even better! :)

It actually looks pretty darn good.

I thought you did a great job! Also huge props for even trying this on your own. To top if off you made me laugh a couple times when you said, "As you can see my hole is quite large." That's what she said and then again when you said, "I have the runs." I was dying. Great video!

Great instructions for being new at this. You just showed the average person that not everything is pretty at first. Their will always be struggles on every job. It's all about the end product. You did great

This is great because you show how frustrating it can be when you are not a pro.

Screw in a thin piece of sheet metal. Once cover with fiberglass bonds and it'd hardened, take screws out and fill holes

I use Eastwoods Internal Frame Coating to convert and prevent rust on the inside of rocker panels. It has a flexible tube with a spray tip at the end which allows you to insert the tube into the rocker panels, and then saturate the area inside completely.

This video had me laughing out loud thank you for sharing and sticking with the video recording! Love the commiseration.

Another option for a quick fix and you can consider me a hack but alot of people will clean it up like you did at the beginning of the video then fill the hole with expanding foam and cut it down to a workable shape then apply bondo over the expanding foam. i have done it in the past with stuff just to keep it going its not proper but itll work to get a few extra years out of something that is otherwise safe to drive.

You go girl! I'm getting ready to do the same thing on my old truck

THANK YOU! You're persistence has motivated me! This is the way when your car is worth as much as the repair lol! Thanks again

Thanks for the vlog. This is going to help more people than you think.

You did it again! Way to be to be persistent. You can do anything with that kind of determination

Body shops... I took my Mustang to a body shop and they said my car was beyond repair.... Funny thing is my frame is still good plus it has stiffners that support the cars strutural integrity... So I will be doing like you and be repairing what needs to be done. You can even buy new car panels with your own model !

If you blow up a balloon and put it in the loose area it will give enough resistance to put the fiberglass resin in place. Then when you finish just pop the balloon and pull it out the back.

Admired the perseverance doing something either everyone is going to complain you should “done correctly” or nit pick. You took on the task, figured it out along the way and it came out great You have my respect. We have the same vehicle but they have gone up in value and I’m going to see how much for them to weld on the 2 pieces

People need to stop with saying oh it attracts water and makes it worse, it's obviously an older car not meant to last forever, it's a cheap fix to make it look better until ya drive it into the ground ffs!!😂 She did an awesome job if you ask me!

I’m inspired TY. I’ve been nervous to start this on my 88 YJ. So I see now how good it will look TY so much!!!

You know what sister, if it looks good from across the street then it’s good for a work car!

Thanks for the positive reinforcement! I’ll get on my project soon!

Lemme put it this way: if it worked it ain't stupid. Good job for a first try.

I would have suggested to cut some stove pipe tin and gorilla glue it over the big holes. Easier and much less messy and use of bondo.

😎 you can be a great teacher motebatin others .this is how I got my driver's license. With someone just like you motebatin me that I can do it .and got my license first try. You are awesome.

You could have filled the hole with foam spray first to fill the void then add your fiber paper and bondo anyway great job

This was such a great video really enjoyed watching it your perseverance is amazing

This is what I did with my rockers except first I took fiberglass resin and mat to hold the bondo in the hole. As soon as it hardens it will sand right down.

thx very much,much respect for your perseverance,and like you said thousand time better than it was

Looks better than the rust for sure! 👍

I know a pro body guy (best I’ve ever met) and he even ends up with runs in a rattle can job.

I'm about to have a go at some rust on my Hilux, if it looks as good as yours I will be more than happy. Thanks for the inspiration.

You're Awesome! You did a great job! I feel your frustration but couldn't stop laughing when you stuck the rubber glove in! 🤣 but it worked! Good for you! Congrats! I might try this since my rocker panels are rocked with rust too.

From what I’ve seen online there’s four ways to fix rust no holes. Spray foam, Bondo, wielding, and slip on covers. I thought we’ll why not try all of them at once? Gonna be expensive and time consuming but worth trying out.

What a lot of work! I respect the work put in.Don’t know if you plan to do more but if you do they make body files and plains that allow fast shaping of the fillers when they’re partially hardened(still soft). These files and planes look similar to a cheese grater. I use them with filler and like them a lot.

You did a great job ! Got creative and got it done. Good for you !

Looks like your patience payed off

Beautiful job. Amazin. 👍

Nice video I also have a 3rd gen with rusty rockers. Hopefully I’m able to tackle this down myself

You did an amazing job!!

Good job !

Rubber gloves, mentioning foreshadowing for more gloves...and the the worry about ticks! "And there's the thing I'm trying to hold so the door doesn't get paint on it...and the door did get paint on it."

My 4runner’s rockers look almost identical. Wow. This is an amazing fix especially since you’re like me!

For never having done this before, I think you did an awesome job. I may have tried putting the mesh on the outside rather than doing it from the inside.

Not allowed to repair cars in this in New Zealand. Has to be tig welded for safety

Perhaps making spray foam molds of those sections will help doing the job easier.

Great job...could you please let me know that what all materials you bought for this and an approximate cost

The question is: what does it look like after 2 years?

On the cheap end Bondo glass is good to work with you would want to make a template of the damage area with waxed paper and Bondo glass the template hold it firmly to the area and your done!!!!😁

La noi in Romania exista un adeziv numit Poxilina. Cu el lipesc orice tabla de alta tabla. V am zis acest lucru pentru ca am vazut ca v ati chinuit foarte mult sa astupati acea gaura.

If your going to fill with fiberglass put the fiberglass on wax paper let the wax paper hold it in place until it hardens.

Great video. Was wondering.. What primer would you suggest on the grinded area of a welded on rocker panel? I don't plan on paint for several months down the road.

Gloves! Those purty hands gonna get beat up!

Those panels are a critical part of the vehicle's safety / crash protection design - good luck in a front or side impact! This work would be illegal in the UK and you wouldn't be insured in the case of an accident. This is scary stuff!

There's great videos for DIY repair by Kurt's cottage. He shows a easy method to do it.

Good job...!!!

Just did this,, but I sprayed foamed Inside after the black coating! Gives the filler alot to hold onto and a good staring shape

Shes acc so funny And pleasant to listen to 😊

Not sure I'm going to follow it but loved your honesty 🙂

Blue Tape will pick up those paint drips to level...then you can just flash it again...😀 (After it dries a little...)

What is the sander you have? What is that sanding tool called specifically? I think I might have something similar, but not sure. Super beginner here… Thanks!!!

Hows this one holding up? Any bubbling?

How has this repair held up one year later?

The rubberized undercoating overtime cracks and traps water and makes it worse. I use either fluid film which is oil based or Rp342 which is wax based same for CRC HD works great too for a very long long time before having to reapply

I do expandable foam first let it dry completely then razer blade it flat and one 2 thins coats of bondo and done

Seen another video guy used spray foam as a filler.. seemed to work great

Don't be afraid to fail while trying..

Even if it was still the fiber glass big chunk. Still way better than that rust 100 percent

Hey :) how long hold it?

Wax paper and masking tape to hold the bondo and mesh up. Oh I see you found a ziplock for it.. lol

Does any rust came since thoes fixes?

When you spray, spray like a robot. Maintain the same distance and speed with your spray can.

gonna try on my 2011 ford fusion! body shop ask for $1700 to fix . lol thanks!

A simple and easy way to create something for the bondo to hold onto is to use a bottle of expanding foam. Spray some expanding foam into the rocker panel and once it expands, you can easily cut off the foam and shape it the way you like it. The foam makes a great backing for the bondo to hold onto once it expands and fills up the rocker panel. Makes working with large holes like this so much easier to work with. You did a great job, considering that bondo can be a pain to work with when it comes to large holes.

HILLBILLY AUTO BODY SHOP , that should be the garage name youd make a killing , you have a HOLE & i have a rubber glove for it some kinda slogan like that lol ay atleast u got it done i woulda just payed to get it welded cause mannnnn gesussssss!

Next time try welding I bet you could do it just fine

This is IMMORAL . STAY IN THE KITCHEN WHERE YOU BELONG!!!

Next time just put a big blob of fiberglass filler on a piece of wax paper and put in place and just keep pressing and holding it in place until it starts to go hard..

You think the pros don't shove things like gloves or paper/cardboard up there?

Next time use expanding spray foam to fill those huge holes.

You could of done it with plexiglass sheets :)

Use foam gap filler next time

I mean. Um. It does look better after. 🙂

Pool noodle

Sa tiendra pas dans le temps sa va éclater car le mastic n est pas fait pour bourré une épaisseur en plus le temps que sa sèche intérieur elle a déjà bombé la peinture sa craquera

Temporary fix! Will hold more water and continue to rust.

Should have been welded there's no strength in that area anymore 😮😮

What is wrong with people? Who can possibly think this is ok? It’s a bloody mess!