How to Remove Rocker Panels From a Chevy Truck

When a Chevy truck ages and is exposed to adverse road conditions for years or maybe decades, the rocker panels take a lot of abuse. Salt can get in between the panels, which forms rust over time. Eventually the panels need to be replaced. This is a complicated process involving cutting, welding and shaping sheet metal, so it's not for the novice car builder. Before you replace the panels, however, you must remove the old ones.

Things You'll Need

• Permanent marker
• Replacement rocker panel
• Drill
• Spot weld cutting bits
• Air compressor with air line
• Safety glasses
• Hearing protection
• Gloves
• Pneumatic angle grinder with cut-off wheel

Instructions

1. Inspect the rocker panel needing replacement. Determine how much of the rocker panel you want to replace; this depends on the condition of the original rocker. Use the entire replacement piece, or just a small section. If you want to cut down the replacement piece, use the angle grinder with the cut-off wheel to cut it to size.

2. Hold the replacement panel over the rocker where you want to cut it, and mark the perimeter of the replacement panel using the permanent marker. Pull off the replacement panel and verify the location is correct.

3. Put on the safety goggles, gloves and hearing protection. Attach the angle grinder with the cut-off wheel to the air compressor through the air line, and cut inside of the permanent marker lines on the stock rocker.

4. Hold the replacement rocker in the hole and verify fitment. If it doesn't fit, trim the hole to size using the angle grinder until there is approximately a 1/16-inch gap between the replacement panel and the stock rocker.

Tips & Warnings

• Always make sure that you cut the hole in the stock panel smaller than the replacement panel, and then use the grinder to trim to size. It's always best to cut smaller than larger, otherwise you could have to fill in more metal than you want to.