Rocker Panel / Sill Rust Repair

[teh]

Hi everyone. 

I am in the process of fixing a few rust issues on my car. It is overall quite solid but there is stuff here and there. Today I found something new that I am not sure how to go about the best way...

There is rust on my rocker panel or to be more precise on the seam (how to call this?!). The rocker panel it self and all the metal surrounding it seems quite solid. 

I am struggling to understand which parts are at play here and how the car is build here. Are there two panels connecting at this seam or is this full part of the rocker panel? 

How would you go about repairing it? Get a replacement rocker panel and cut out a piece?

Any input is appreciated!

 

[CanadianMiniFan]

The outer sill or rocker comes down the side of the car, flattens, and then has the lip bent into it. That lip is spot welded to a vertical flange of the floor pans, and then the outer sill bends 90* around the floor flange, and that 90* space is filled with a sort of thick schutz or sealant. To know how to fix it, you have to see how bad it is. The schutz undercoating has preserved these cars well, however when rust bubbles through, it can be a lot worse under the schutz. You have to grind down to clean metal and see what you are working with. If you have no perforation, you might get away with POR15 or some other rust encapsulating paint, and re undercoat. But I guarantee in the seam between the sill and floor there is rust, but if it’s well protected, likely won’t spread. You have to decide how deep you want to go. The seam probably has rust between both panels the whole way down. If you spray wax in the sill cavity, and aren’t using it in winter/salt, it could never be a big issue 

[JohnH]

These pics may help a bit;

 
  
 

 




 

[JohnH]

Tools used.

 


 


 





 

[teh]

Thanks CanadianMiniJohn for the explanation and thank you John for the pictures. They indeed help me understand (and slightly scare me). Looking good what you did there. Thank you for also including the tools. I need a shear like that!