Rocker cutting goodness

[Ted_Z]

While I was very temped to buy this kit from these guys I ending up going at it on my own for the ZJ. I will say that while it didn't use their kit, I did take inspiration from their design, so many thanks to Spadano.

We cut the original rocker out, and the bottom of the pinch seam. My driver's side rocker had been crushed a few years back by a tree, despite having sliders. In fact the pinch seam was wrinkled a bit because of the upward pressure from the sliders. Once the outer rocker and pinch seam was removed a new piece of 2"x3/16" flat was over-laid on the original inner rocker (welded both sides). The bottom of the A-pillar and B-pillar structure was tied to the reinforced inner rocker. The replacement outer rocker was a piece of 3"x6" rectangle, 3/16" wall. We split it long ways to create a pair of lop-sided "C" pieces, 3" tall, 5" on one leg, 1" on the other. It was then welded to the new inner rocker and to the remnants or the outer rocker. The piece was rolled at an angle slightly to clear the pillars structures and put the bottom seal close to the bottom edge of the new inner rocker.

Looking back, I don't know if this is the strongest way to do your rockers, but I know it will be stronger and have more clearance than what I had. John and I spent about 10 hours over 2 days (not counting cleaning up). most of the time was spent cutting and prepping. Splitting the 3x6 in two took about 45 minutes, so in the end I don't know if buying the kit would have saved me as much time as I originally thought. I did also have to take a trip to the local metal yard and haul it all home, vs metal showing up at my door.

[Ted_Z]

I forgot to add, I still need to install a couple tie ins to the unibody "frame" and weld on the tubular outriggers.

[JohnBoulderCO]

The first pic and last pic aren't visible.


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[K2]

Did you fix the t-case?

[Ted_Z]

The 231 is a basket case. So I'm running my old 242 for now. When are we going to hit the JY and get you a 231 too?

[JohnBoulderCO]

The failure mode was not the same as my 231. I was hoping it was so maybe we could learn something and do preventative maintenance.


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[K2]

I will be around the next few weekends, let me know what works for you.

[4FishLimit]

I know this thread is a few months old, but any pics of the finished product?

I cut out the outer rockers on my WJ a while back in prep for something similar. I like the way you reinforced the pinch weld and were able to tie in the A and B pillars.

[Ted_Z]

I can post some up this weekend. In the meantime try this link, the last few seconds of the video you get a good view of the final results.

https://drive.google.com/open?id=0B2...i0yU1ZXOElReFE

BTW, that is "High Dive" on the Behind the Rocks trail in Moab, UT.

[Ken L]

Nice driving!!

[K2]

You should do a write up on seat cleaning!