Cargo rocker replacement

DukeBradbury · Posted: Tue Sep 06, 2011 2:16 pm Post subject: Cargo rocker replacement

I did a search and found a lot of valuable information. However, I still have a couple questions I was hoping that I could get answered.

I removed the old outer rocker and strengthener. I removed both together by drilling out the bottom spot welds and separating the outer rocker/strengthener assembly from the inner rocker.

My inner rocker is still good.

It didnt appear that the top of the outer rocker/strengther assembly was welded to much. I found welds in the middle where the cargo doors close at, but besides that, it didn't look like there were any welds. Is this correct?

How should I weld it back in?

I had planned on plug welding the bottom. Welding the top corners and bottom. Welding the middle where the cargo doors meet. Possibly a body panel adhesive like this at the ends.

Should I do any additional welds?

Thanks

BarryL · Posted: Tue Sep 06, 2011 7:01 pm Post subject:

It should have had several weld across the threshold/floor area. maybe your bus was made at 4 PM the day before Oktoberfest.

KombiMarc · Posted: Tue Sep 06, 2011 9:19 pm Post subject:

Duke
Mine had many spot welds across the top of the inner, see middle of 1st page on my rebuild thread, hope it helps. Pics?
Thx build link in my signature.
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BarryL · Posted: Wed Sep 07, 2011 7:26 am Post subject: Re: Cargo rocker replacement

DukeBradbury · Posted: Wed Sep 07, 2011 11:57 am Post subject:

Here is what I started with:

Image may have been reduced in size. Click image to view fullscreen.

Located the spot welds:

The rocker removed:

There is some surface rust on the inner rocker as you can see. However, it is very solid and I am going to hit it with the sand blaster.

I was able to straighten out the outer edge of the floor, leaving the lip of course! (see the last couple pics). However, if you check out the first couple pics you will notice that it isn't in the best shape. (rust damage). Not bad. What do you think. Should it be replaced?

DukeBradbury · Posted: Wed Sep 07, 2011 11:59 am Post subject: Re: Cargo rocker replacement

DukeBradbury · Posted: Fri Sep 09, 2011 10:47 am Post subject:

Barryl,

When spot welding the bottom, did you weld from the inner rocker side, or outer rocker side?

I was thinking that I could drill holes in my inner rocker and weld from the inner rocker side to attach my outer rocker/strengthener.

What do you think?

Major Woody · Posted: Fri Sep 09, 2011 4:44 pm Post subject:

I plug welded the bottom from the back. Much easier to clean up that way and the back side of a plug weld often looks kinda like a spotweld.

BarryL · Posted: Fri Sep 09, 2011 7:03 pm Post subject:

krusher · Posted: Sat Sep 10, 2011 12:55 am Post subject:

vwjim · Posted: Sat Jan 07, 2012 5:01 pm Post subject:

Do you have any photos of how you modify the strengthener panel?

With the B&C post inner supports replaced I can't see how to feed the outer rocker into position if the strengthener is pre-welded to it without cutting some of the strengthener away.

Thanks.

ccb_dan · Posted: Sat Mar 09, 2013 2:52 pm Post subject:

OK so I got my outer rocker off and found out my inner rocker is toast! Which is OK because I bought the inner and outer just in case.

So my question is how do I get the inner rocker off? I have to replace the outer floor anyway so would it be easiest to remove the floor first then the inner rocker?

Thanks!!!

Jerry · Samba Member Joined: October 28, 2007 Posts: 1367

I would buy the outer 10" first, then cut out accordingly, then inner, outer, floor.
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ccb_dan · Posted: Sat Mar 09, 2013 5:06 pm Post subject:

Thanks Jerry. I have the outer floor piece already so I'm all set there, just looking for some guidance on removing the inner rocker. If I cut the outer floor first will it be easier to remove the inner rocker piece?

Also, when welding it back together are you saying the order is to weld the inner rocker, then the outer rocker then lastly the floor section?

ccb_dan · Posted: Sun Mar 10, 2013 2:19 pm Post subject:

OK, did a little more cutting and I am wondering 2 things...

1. How do I get the small rocker section behind the rear cargo door off? Just hold the new section up, mark it with a sharpie then start cutting?

2. Not sure if I need to replace the jack point at the front cargo door. The jack point itself feel super solid but after I got the inner rocker removed it looks nasty. Thoughts?

Jerry · Samba Member Joined: October 28, 2007 Posts: 1367

The tab that strengthens your rocker is toast, if it were me, I'd remove the jackpoint, cut the inner & outer b-pillar flush with the floor, remove the rest of the inner rocker then replace from there.
You could actually do the replacement without removing the jackpoint but I'd go ahead & replace it while you're at it.

Klassicfab can get you the lower b-pillar below the hinge.... they're not that much $$$.
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ccb_dan · Posted: Sun Mar 10, 2013 4:42 pm Post subject:

Thanks Jerry. So you think I need the lower B Pillar and the jack point huh?

So to do that whole area what pieces do I need? The B Pillar, outrigger and jack point? I guess I should probably just get the same stuff for the rear and do that while I'm at it too huh?

Might as well do it while I have things opened up!

Z · Posted: Sun Mar 10, 2013 6:35 pm Post subject:

ccb_dan · Posted: Mon Mar 11, 2013 7:15 am Post subject:

Thanks Z. I'm ordering the jack point/outrigger stuff today. Gerson says I might be able to get it by the end of the week.

jeffreyned · Posted: Mon Mar 11, 2013 8:50 am Post subject:

When I attached my outer rocker panels I plug welded from the front, which works, but then you have to clean them up a bit, which isn't hard. That being said, if I was doing it again I'd do like Major Woody says and plug weld from the back. Clamping is key to make sure the two flanges are touching. I'd use a small pair of vice grips on either side and as close together as you can and still weld. -That is if there is any chance of gap- yours might be all nice and flat and smooth... but if you're using the existing inner rocker it might be a little wavy.

Looks great the way you're going. Nice work! Cool

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