I removed my step bars last night and today, because they're rusted badly and I'm considering getting them Line-X coated. After the trouble I had with broken bolts and rusted bolt-bosses, and seeing the actual condition now that they're off the truck, I'm not sure I'll proceed. But.... that's a whole other story.

While under the truck grinding and cutting brackets off, I found a hole in the leading edge of my driver's side rocker panel. I then found a soft spot halfway back, as well. (The truck is a '99, but has only been in Ohio for four winters.) THEN I noticed that when Ford added the step bars, they did not install/re-install a rubber plug intended to keep water and other crap out of the rocker!!

Please enjoy my short video commentary.

http://www.youtube.com/watch?v=tGyUyApQNd8

Ford engineer/installer =


Now, the question is, what can be done about it?

Andy

 

Hey don't push on that to hard lol, at-least yours is still in one piece for now. You can bust your *** trying to fix that one, only for it fail again soon after, or just install a new one. I've tried to fix that, but unsuccessful since I didn't remove all the cancer. I really couldn't, there wouldn't be nothing left!

Just replace -

http://raybuck.com/c-54832-repair-pa...ight-duty.html

 

I wasn't pushing that hard, really! I don't think I could put my thumb through it, but a screwdriver would do it in, for certain.

I assume that's a cut-and-weld operation, not an install-over-existing?

Andy

EDIT: And you can bet I'll pick up a couple plugs to fill those holes whether or not the step-bard go back on!

 

Yea, I seem to cause more trouble poking things like that then it's worth. Same thing happened, removed my factory running board and couldn't believe the rust.

Below the body line on both sides of the bed are gone on mine as well

Actually, my panels should be here tomorrow for that.

Right, you weld them in. I purchased a cheapy, a $80 Flux core wire feed welder, but I hear you can glue them in for a permanent repair. That RayBucks site sells some of that, but I've heard 3M makes the best adhesive if you go that route.

For painting/ -down to metal, then use "Self Etching Primer" and nothing else or even the new stuff will rust back thru. They sell that primer everywhere, even Walmart lol.

Yea, my Rubbers were missing as well. They most likley just jump ship themselves somewhere sometime I expect. Patch those holes with something after you treat the inside as best as you can.

LineX or Pore Series to cover, - if your doing it all yourself. I absolutely hate body work and so does everyone else, - that's why they charge so much ( :

 

So the Raybuck's part installs over the existing rocker panel?

Andy

 

No, I don't think so , why ? I'd just replace the part. It's easier IMO and how would get rid of the seam? I don't think you could do that on a rocker anyway, it wouldn't fit.

 

That's what I thought, but when you referenced gluing it in, I thought maybe I was missing something.

I'm having body work done on the other side of the truck soon, and maybe I'll talk to them about doing this at the same time. Might save me some materials costs, at least.

Or.... I could blast/vacuum out as much rust and dirt as I can, and pour in something to seal up and reinforce it for awhile. I was thinking garage-floor epoxy would be pretty tough stuff, and would seal up well. Maybe some rubberized undercoating, or bedliner material?

I'm half joking about the "temporary" solution, but really do wonder if something like that would work for any significant period of time.

Andy

Oh, and that rubber plug was never there in the first place. Both sides are missing. It would be behind the front mounting bracket for the step bar, and would require some trimming to make it fit right. (The quick nuts go through the opening.) I'll pull a couple the next time I'm at the junk yard and make them work, though.

 

3M has undercoating in aerosol at the stores, but it's a PITA to treat the inside of the Rockers. Get what yo can, then hose the insides down with oil, wd40, drylube or whatnot. -Cap them off.

 

I guess it can't hurt to try and prolong the inevitable. I'll have to see what kind of savings there might be doing this with the other work first. Thanks for the input.

Andy