As far as rust goes this was the worst part on the truck. Like any major repair it is much easier to just take it one step at a time. Here you can see all the pieces laid out in poster board to make the needed repair.

All effected rusty metal has been removed and the pieces are fit together. This sequence can be transferred to most any FC floor repair. A systematic approach always seems to work best.

A temporary backer is clamped into place to support the new pieces to be added.

The new lower sill and pillar post are now welded in place. A few stitch welds and we’re good to go!

The pillar structure is now complete and it’s time to fabricate the outer skin to close the panel out.

The outer skin template is fitted to the body.

…..and welded into place. This repair is now in the history books complete with a new rocker panel. Details on the rocker are shown later.