2011-2014 Rocker Panel/Cab Corner DIY replacement

2011-2014 Rocker Panel/Cab Corner DIY replacement

This is a discussion on 2011-2014 Rocker Panel/Cab Corner DIY replacement within the F150 Ecoboost Guides and How-Tos forums, part of the F150 Ecoboost Garage category; So I scoured the internet in my search on how to fix this notorious problem and couldn't find much of anything. So, I decided to ...

Results 1 to 5 of 5
Like Tree4Likes
  • 2 Post By kcoop99
  • 2 Post By R0bCincy

Thread: 2011-2014 Rocker Panel/Cab Corner DIY replacement

  1. #1
    Ecoboost Jr Member kcoop99's Avatar

    Join Date
    Jun 2016
    Posts
    38
    Member #
    16216
    Liked
    3 times

    2011-2014 Rocker Panel/Cab Corner DIY replacement

    So I scoured the internet in my search on how to fix this notorious problem and couldn't find much of anything. So, I decided to watch as many Youtube videos (on other vehicles) as I could and find the parts to do this myself. Since I couldn't find much of anything I thought I would put how I did it here in hopes someone else will find it. Full disclosure here, I am NOT a professional body guy and this may not suit all of your needs but with my 2011 FX4 SCREW that has 230,000 miles I thought I might get myself another 3-5 years out of this.

    I did not and could not do a complete replacement like the pros would like to do as it was going to run around $3000. I found SLIP ON ROCKERS here. I then decided to go with POR 15 as my rust preventer of choice. I used the metal prep (EXTREMELY important on the new rockers as well as any non rusted areas you intend to use POR15), Rust preventer, top coat, then finally the bed liner. One quart of each was all I needed. I used the spray can of the top coat. It is important to follow the directions on this stuff to a "T"!

    I did not get ALL the pictures along the way but here is what I did get:

    Cut away all of the old rust!! Make sure and not cut too much as you need something to rivet (I used rivets in this case rather than welding):
    Name:  Photo Aug 05, 8 24 51 PM (1).jpg
Views: 644
Size:  28.8 KB

    Here is the rocker panel. I had to cut some of it off as it would normally go all the way up the door into the step (before and after shown). I needed it to just go up to where the plastic clips are located to hold the weatherstrips. Also you will need to use the metal prep on these panels as the POR15 needs something to attach to:
    Name:  Photo Aug 10, 9 23 41 AM (1).jpg
Views: 410
Size:  70.0 KB
    Name:  Photo Aug 10, 9 23 50 AM (1).jpg
Views: 462
Size:  71.7 KB

    Painted with POR15 rust preventer:
    Name:  Photo Aug 10, 12 01 07 PM (1).jpg
Views: 450
Size:  39.6 KB

    After loose rust is ground away and metal is prepped, I coated the all surfaces I could reach with the rust preventer:
    Name:  Photo Aug 09, 2 12 26 PM (1).jpg
Views: 470
Size:  39.0 KB
    Attachment 151977

    I did not have a helper but one would be great for this step. After measuring and cutting the panels in the previous steps, line up the panels and drill holes for your rivets. I went every 2-3 inches for a secure fit:
    Name:  Photo Aug 10, 3 55 21 PM (1).jpg
Views: 463
Size:  33.3 KB
    Name:  Photo Aug 10, 7 30 05 PM (1).jpg
Views: 550
Size:  28.3 KB

    This was the easy part. I do not have pictures of the mess that ensued from here but you can see at the top right of the pictures the gap that is/was the rusted cab corner. Now, don't tell the professional what I did here and if you are going to knock me for this, stop reading now; I simply built up the corner with bondo. Lots of layers of bondo. Will it hold up over time? I don't know but it worked great for me.
    After:
    Name:  Photo Aug 17, 8 36 36 AM (1).jpg
Views: 457
Size:  31.4 KB

    Not pictured is the seam you get just above the rivets. I used the same bondo to fill the seam and sanded the seam over the rivets. I can attach better pictures later. The spot where I chose to cut and rivet is right where the weather strip is so it will hide most imperfections. Also, I used the bedliner to cover up any other imperfections.

    Once I had the seams sanded and ready for top coat, I used an 80 grit flap wheel on my angle grinder to sand down to the bare metal. This is the REAL point of no return as you no longer have paint!! Once sanded, again it is extremely important to use the metal prep here so your preventer will grab to the metal.
    Name:  Photo Aug 16, 3 08 56 PM (1).jpg
Views: 430
Size:  32.5 KB
    Name:  Photo Aug 16, 6 11 17 PM (1).jpg
Views: 440
Size:  32.6 KB
    Name:  Photo Aug 16, 6 11 22 PM (1).jpg
Views: 451
Size:  25.6 KB
    Name:  Photo Aug 17, 8 36 25 AM (1).jpg
Views: 451
Size:  35.8 KB

    I used the top coat in the pictures above because I was not quite sure on the bedliner. I don't think I needed it. However, if you do NOT use the bedliner you will need the top coat as POR 15 will fade in UV light so a top coat is necessary. Here is the final product:
    Name:  Photo Aug 30, 2 14 19 PM (1).jpg
Views: 445
Size:  30.2 KB
    Name:  Photo Aug 30, 4 16 52 PM (1).jpg
Views: 483
Size:  62.4 KB
    Name:  Photo Aug 30, 6 35 43 PM (1).jpg
Views: 455
Size:  39.1 KB
    Name:  Photo Aug 30, 6 36 20 PM (1).jpg
Views: 468
Size:  36.9 KB
    Attachment 152000

    So how do we prep for future "damage"? Well, the body guy I spoke too said it probably wouldn't be a bad idea to drill some holes underneath to actually allow water to escape. I didn't do that (yet) and I did remove all of the stupid tape that Ford put on there from the factory as most of it was gone or damaged already. I used a wire brush to remove rust and loose dirt around the holes in the frame and used a 3m Flashing tape to cover them back up. This stuff is STICKY AS HELL. It is thin so I doubled it up on all the holes. After it was all said and done I sprayed the exposed rivets and the back of the frame with the top coat.
    Name:  Photo Sep 09, 7 00 53 PM.jpg
Views: 439
Size:  4.51 MB
    Name:  Photo Sep 09, 7 06 25 PM (1).jpg
Views: 459
Size:  28.0 KB

    And that was just one side........It was quite the undertaking and I don't think I want to do it again but I think it looks GREAT and hopefully will hold up for several more years. I hope this helps someone else if you decide to tackle this project.
    Last edited by kcoop99; 09-09-2018 at 10:37 PM.
    bespurcell and Mikedick77 like this.

  2. #2
    Eco-Beast winchested's Avatar

    Join Date
    Aug 2013
    Location
    Southern Ontario, Canada
    Posts
    6,583
    Member #
    2128
    Liked
    2658 times
    Looks like every ol rotten truck you'll find in salted roads parts of Canada. As long as it gets you your expected life out of the truck who cares eh.

    This repair reminds me of my Grampa and uncles way of doing body work...


    The cab corner won't last. At least you didn't fill the rockers with foam...
    2011 XLT Screw 6.5' Box, Tux Black, 4" BDS lift, 34" BFG KO2 tires, 18x8.5" +18 XD spy Wheels, PTM oem Flares. Rampage Slimline nerf bars. 5* Tuned 87 P/T.

  3. #3
    Ecoboost Pro waterbuffalo's Avatar

    Join Date
    Oct 2016
    Posts
    947
    Member #
    22266
    Liked
    365 times

    2011-2014 Rocker Panel/Cab Corner DIY replacement

    It looks good. Not sure how long that will last but here’s what I did, I didn’t have that much rust.


    2012 screw 3.5L

  4. Remove Advertisements
    F150EcoBoost.net
    Advertisements
     

  5. #4
    Ecoboost Pro waterbuffalo's Avatar

    Join Date
    Oct 2016
    Posts
    947
    Member #
    22266
    Liked
    365 times
    I had rhino liner sprayed on by Ziebart in our area. I only had some water bubbling through the paint and some rust starting. This stuff should hold it all together for next next ten years or so (even if it rust behind it), It was 1,200$ and they hit under the wheel wells too. It makes all the visible rust disappear.

    I use spray oil for the rest.


    2012 screw 3.5L

  6. #5
    Ecoboost Regular R0bCincy's Avatar

    Join Date
    Apr 2018
    Location
    Cincinnati, OH
    Posts
    206
    Member #
    59570
    Liked
    56 times
    Quote Originally Posted by kcoop99 View Post
    So I scoured the internet in my search on how to fix this notorious problem and couldn't find much of anything. So, I decided to watch as many Youtube videos (on other vehicles) as I could and find the parts to do this myself. Since I couldn't find much of anything I thought I would put how I did it here in hopes someone else will find it. Full disclosure here, I am NOT a professional body guy and this may not suit all of your needs but with my 2011 FX4 SCREW that has 230,000 miles I thought I might get myself another 3-5 years out of this.
    .
    Nice work and thanks for the write up. I like it. Only change I would have suggested would be to buy the cab corner replacements ($80) cut them to the size you need and use body adhesive to connect to truck. Not perfect, but an extra hundred bucks would add years over the bondo.
    waterbuffalo and kcoop99 like this.
    2011 FX4 SCREW, 3.5 EB. 3.73 and 5* and MPT Tunes, SW catted DP and SW 3.5 inch Chambered Exhaust, AFE Stage 2 Intake, Mishimoto CAC, and very rusty cab corners.

Sponsored Links

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  

Similar Threads

  1. Cab corner replacement
    By R0bCincy in forum F150 Ecoboost Maintenance
    Replies: 53
    Last Post: 03-15-2019, 08:44 AM
  2. Dreaded Rocker panel replacement
    By kcoop99 in forum F150 Ecoboost Appearance
    Replies: 2
    Last Post: 08-05-2018, 09:16 PM
  3. Not Eb specific: inner rocker panel tape.
    By winchested in forum F150 Ecoboost Problems
    Replies: 13
    Last Post: 05-25-2018, 11:50 AM
  4. With summer around the corner Let's see the boats
    By sloans4x4 in forum F150 Ecoboost Towing
    Replies: 60
    Last Post: 04-27-2017, 01:49 PM
  5. DIY Fiberglass Aux switch panel and iPhone dock
    By skern240 in forum F150 Ecoboost Accessories
    Replies: 4
    Last Post: 03-25-2014, 03:12 PM

Search tags for this page

diy rocker panels

,
rocker panel rivets diy
Click on a term to search for related topics.

Tags for this Thread

Connect with us: F150 Ecoboost Forum on Twitter F150 Ecoboost Forum on Facebook F150 Ecoboost Forum RSS Feed
Find us on Google+