How to Cut Off Rocker Panels

In the world of lowered trucks, there's low, and then there's really low. First, they modify the suspension to sit the frame on the ground. Then, they modify the body to set the body down over the frame and onto the ground. But the really hardcore, drop the body past the frame, and cut off the rockers, which lays the door on the ground. But doing this isn't an easy process, and it takes some skill to do it right.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• Tape measure
• Permanent marker
• Masking tape
• Safety glasses
• Hearing protection
• Reciprocating saw
• Metal blades
• MIG Welder
• Welding helmet
• Welding gloves
• 20 feet of 3-inch wide, .250 wall flat steel
• Angle grinder with grinding discs and 80-grit flap wheel

1. Measure from the bottom of the frame to the rocker using the tape measure. Scribe a line across the rocker on the exterior of the chassis, that puts the rocker level with the frame. This is your cut line, so scribe it all the way around the truck using the permanent marker.

2. Mask the area just above the permanent marker line with masking tape. This will be easier to see when you're holding the reciprocating saw, and give you a good guideline on where to cut.

3. Put on the hearing protection and the eye protection.

4. Insert the metal blade into the reciprocating saw, and cut along the marked line. Start from the rear of the cab and work forward, holding the reciprocating saw at as tight an angle to the body as you can. If the saw is at a 90-degree angle to the cab, it's not correct. By keeping the saw at a tight angle to the cab, you ensure that the cut will be as straight as possible.

5. Measure the length of the cab using the tape measure and cut out a section of the 3-inch flat steel to match that measurement using the reciprocating saw. This will be your new rocker panel, and will sit 1/4-inch lower than the frame.

6. Put the flap disk into the grinder and clean off all of the paint about an inch up from the cut. Do this to get a good weld on the steel. Do it on the inside of the cab as well, because you'll be welding both sides.

7. Weld the steel to the cab by welding in short bursts, with beads no longer than 1/4-inch at a time, using the MIG welde, the welding helmet and gloves. This ensures that you don't warp the sheet metal by getting it too hot. Move around frequently, never welding within a foot of another weld until it has cooled down. Repeat this process until all of the welds are connected, on the underside of the cab and the outside.

8. Grind down the welds using the angle grinder with the grinding disc, then move on to the flap wheel for more precise grinding. The rockers have now been removed and new ones installed.

Tips & Warnings

• Always have a fire extinguisher handy when you're welding.

References

• Traditional body drop on a truck