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The Driver's Side
(05/30/04) The rust on the left side rocker panel was just the opposite of the right. The bottom of the panel was in good shape, but the top was trashed.
In order to get the floormat out, you have to remove the throttle pedal. It's held in place by two phillips head screws. Of course they were rusted solid, just like every other fastener on the truck. So I had use the old grinder to take those out, too.
It wasn't pretty under the floormat, either. That pile of globs in the foreground is the silicone rubber that had been used in an attempt to seal the holes. I guess it was halfway effective.
The right side has the same problem. It looks like were gonna be fabricating some patch panels.
After removing the mat and the sound deadener, then vacuuming, it's not all that bad except for the corner of the floorboard and the rocker panel.
Speakin of the corner area, here it is. I think I can make patches from the same galvanized sheet metal I used on the left rocker panel. We'll see.
(06/04/04) I got distracted with some other stuff (next page or so) but eventually I got back to the left rocker panel. It ain't lookin too good.
Matter of fact, it looked downright awful once I got the whole thing off.
Even when I did a test fit there were still gaping holes...
...so I started fabricating a sub-patch panel. This was its status on 06/06/04.
(06/10/04) Here's the sub-patch panel pop-riveted into place and primed.
And then I riveted the replacement rocker panel in.
(06/14/04) Then I started workin on a patch for the "tire inspection opening." It was REALLY rotted out in that area. So I thought about it for a while and this is the shape of the patch that seemed to make the most sense.
I had to add a few more pieces, kinda making a patchwork of patches. At least I think all the holes are covered.
Here's the whole mess with the Mr. Gasket throttle pedal set in place. I'd had to grind off the remnants of the bolts for the old throttle pedal and this one seems to fit ok.
Next page: The beautification project continues.
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