replacing/removing rocker panels and floorboard

[Blanco_53]

Like the title says, i'm looking to replace the rusted out rockers and floorboards. My question is what is the correct way/process of removing and replacing them and what tools will i need?

[BR3W CITY]

Do you have a welder?....thats kind of the big one.

Are you doing it with the cab on or off of the frame?

If you check out my build, I have a good chunk of a page on my process and pictures (its broken up in a few posts, so you have to go through it a little to see the start-finish)
I did it with body on frame as all of my cab supports were in decent shape; started by doing initial measurements to make sure things didn't move around.

I cut out the outer rocker, peeled it away from the inner piece, then started to cut the floor sections out. I used cardboard to mockup some patches, then cut the metal and did little stitch welds to get it in without using too much heat. Take it slow, keep it square and you should be golden. Its a bit more of an art than a science.

If you have the cab off, or are doing major sections of the floor including cab supports, grab tube stock and weld in some braces in an X to prevent things from shifting.

You need a GOOD welder w/ gas..NO FLUX CORE
Grinder w grinding and cutoff discs (and or a torch or plasma if you use those to cut)
measuring tools, a scribe
welding clamps help a lot, as does a welding copper spoon to avoid burn when you transition from new panel to any "questionable" areas.

[mud.man.rj]

I agree, remember as mentioned to take it slow, step back a think about each step, measure things and have the replacement pieces there ahead of time to use as a reference, you will need them. leave extra when cutting, can be finish trimmed later to exact measurements. I just did both side on mine, inner/outer rockers/cab corners and doors, took way longer than i thought, but straight now.

[ozzyman]

I should have a good amount of photos in my build for removal, havent gotten around to replacing yet, need to get home before that happens

[trelogix]

Also be prepared to take the doors on and off a lot, as well as the front fenders. If you're using repop replacement panels they will not fit the same as the old ones and its important to make sure things are lining up correctly. As mud.man.rj said, take it slow. I recently did both sides of my cab (rockers and outer floor pans) and it took 3 days to do the first side and two for the second. But then, I tend to "sit back and think" on thing quite a bit. Once its all in you may still find yourself using a 2x4 and 3lb finesse hammer to get things settled in correctly.