Welding thin rockers on a car

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I have some holes in my rockers and would like to repair the holes vs. replacing the whole rocker. I was thinking of using a tig so that I can do micro welding. If possible which type of weld would be best, over lap then fill with bondo or flush butt weld. I have has issues there thin metal vaporizes when hit with welder.
Reply:Yea,, you don't want to do that.... What you see on the outside is really no evaluation of the "rotted" area, much of your rocker is at 50% ~ 70% ~ 90% and the 100% you see. The only way to know is to start abusing it and see what takes the punishment ~ hehe. I know what your thinking, why replace all of it when only 10% "looks" bad but, in the end, it's So Much better and actually less work that you think, to go with a new one.If you're dead-set on just doing a repair, here's a good vid with excellent procedures ->
Reply:there are other post on here about auto panel replacement.  after 35+ years of doing it, mig was the preferred way.  back then, .023-5 wire and 75-25 gas.  start in middle of hole weld to outside edge and around edge to start.  use  3/8  hole.  rockers are usually thicker metal than quarter panels because the rockers are usually a structural part of the car.lincoln 125spmonkey wards 250 ac/dcmiller 211 w/spool gunahp  200 sx tiglotos ltp5000dof course duramax diesel
Reply:If you're just going to do the quick butcher, just stuff the holes with fiber glass and bondo over it. It won't last, but your fix is going to rust out beside all the welds too. I've seen the fiberglass last a couple years... I've also seen it fail in 2 weeks.250 amp Miller DialArc AC/DC StickF-225 amp Forney AC Stick230 amp Sears AC StickLincoln 180C MIGVictor Medalist 350 O/ACut 50 PlasmaLes
Reply:i forgot to add to use weld thru coating on all weld areas.lincoln 125spmonkey wards 250 ac/dcmiller 211 w/spool gunahp  200 sx tiglotos ltp5000dof course duramax diesel
Reply:This rocker has punched holes on the inside of the rocker like an aircraft. Mine is in great shape there but I was thinking of adding a 14 ga plate over those holes to stiffen the rocker. This is a Japanese car so the metal gauge is a bit more then tin foil. I too have 35+ years experience...... actually 45 and know once you dig into a job like rocker replacement you just added 6 months to the job and by the time you uncover all the rust like the plenum/firewall...you just started building a car from the frame up.  unless you have the gas monkey garage or lots of time, its a never ending project.
Reply:I see people put down a series of tacks with MIG, spaced out to minimize distortion, and just go around and around till you're panel is welded out, then grind flat. If you do a lap joint, I've seen people screw the panels together, weld it out, then take the screws out and weld the holes shut. Poor mans Clecos, I guess. Worked well though. Sent from my SAMSUNG-SM-G891A using Tapatalk
Reply:Originally Posted by johnfinThis rocker has punched holes on the inside of the rocker like an aircraft. Mine is in great shape there but I was thinking of adding a 14 ga plate over those holes to stiffen the rocker. This is a Japanese car so the metal gauge is a bit more then tin foil. I too have 35+ years experience...... actually 45 and know once you dig into a job like rocker replacement you just added 6 months to the job and by the time you uncover all the rust like the plenum/firewall...you just started building a car from the frame up.  unless you have the gas monkey garage or lots of time, its a never ending project.
Reply:An air powered punch/flange tool helps make welding panels in much easier, and the results usually are much cleaner. $35 at harbor freight (easy same day exchange) is where I would get it.  They're likely all made in the same factories at the lower level.
Reply:Originally Posted by SlowBluesAn air powered punch/flange tool helps make welding panels in much easier, and the results usually are much cleaner. $35 at harbor freight (easy same day exchange) is where I would get it.  They're likely all made in the same factories at the lower level.
Reply:A piece of copper as a backer, mig welder to fill.But first drill each rust hole to get a clean edge. If after drilling the edge isn't clean and full thickness, drill or grind that area until you get full thickness.Major rust, like my plow truck, gets replaced: https://weldingweb.com/vbb/threads/7...irs?highlight=Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Is this Japanese car a Miata?  Very common for the rockers to rust out.  As said, if you're seeing it on the outside the inside is GONE.  A couple decent YouTube videos on repairing them.
Reply:I hate rust repair! I did so much as a teenager! It isn't a permanent fix if you replace only the rusted through portions, and what isn't yet rusted through is rusted very thin.Overlap welds give a place for corrosive road salt & water to hide & rust again. Only hope is a butt weld. Cut away to sound metal, fashion a patch fitting very close. Much auto sheet metal is inaccessible for dolly & hammer work, I'd favor MIG there. Where you can get a dolly in to hammer the Heat Affected Zone back to correct dimension, I'd choose TIG.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.