Rusty Rotted Rocker! How to Replace a Truck Rocker Panel!

Salty wet roads and water build up are nightmares for body panels on any car or truck, especially here in New England, where we get our hands on older vehicles. When rust and rot strike, some folks send their ride to the scrap heap, or trade it in. But with a few tools, time and elbow grease, you can repair damage and decay on your vehicle you'd rather not part with! Watch this video to see how Andy replaces a rocker panel on our GMC Yukon. The techniques you'll learn can be applied to any steel bodied vehicle!

Check out the other body repair videos we have done!

This repair was done on a 2004 GMC Yukon XL 1500 SLT 5.3L Sport Utility 4-Door Automatic and the process should be similar on the following vehicles:
2000 GMC Yukon XL 1500
2001 GMC Yukon XL 1500
2002 GMC Yukon XL 1500
2003 GMC Yukon XL 1500
2004 GMC Yukon XL 1500
2005 GMC Yukon XL 1500
2006 GMC Yukon XL 1500

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⚠ DISCLAIMER:
While 1A Auto strives to make the information provided in this video as accurate as possible, it makes no claims, promises, or guarantees about the accuracy, completeness or applicability of the content. No information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. All do-it-yourself projects entail some risk. It is the sole responsibility of the viewer to assume this risk. 1A Auto is not responsible or liable for any loss damage (including, but not limited to, actual, consequential, or punitive), liability, claim, or any other injury or cause related to or resulting from any information posted in this video.

[AAuto]

√ *Watch the Video*
√ *Do it Yourself*
√ *Save Money*

[flyguyphil]

Great video, RIP anyone who was wearing headphones

[kevincabral]

No wonder the body shop is so expensive. That is alot of work them guys do and that was just one side. Im gonna attempt it. Great video. Appreciate the material.

[jerryp]

Please don't stop doing these videos. I just bought parts from you guys instead of Rockauto just cause I know you guys put a lot effort into this.

[bobmcl]

Good clear explanation. I always wondered how a rocker panel replacement is done. This helps a lot. Big job, so the rest of the car better be worth saving!

[mjb]

If you do this and there is rust on the inner rocker panel you should replace it at the same time. Leaving the rusty inner panel will cause the new panel to rust out in much less time than it would otherwise. Most vehicles have inner and outer panels.

[pigseye]

Great job! What I like the most is that you did it with fairly basic equipment and canned spray paint. Just shows what you can do without investing a ton of money into tools, welders, and paint spray equipment.

[lightsimage]

As an owner of a rusting NY '02 Avalanche this video was excellent for an amateur guy like me. You did a great job explaining. Sorry some of the comments had to be from "Pros" who want to critique welding and such.
No matter, maybe they can find a welding channel to go and compare their rod sizes...
Thanks!

[jeffreyokun]

Really detailed and nice video. Doing these kinds of jobs myself, I appreciate the common sense and craftsmanship in the video. A car this old does not have to be like brand new and it would not be cost effective to treat it in such a way. What I especially enjoy is how the amount of work is shown here. Bodywork is very labor intensive, especially when the goal is to have good results. Most people think you can do it quick and dirty and complain on the expense of bodywork. This vid shows well how much is entailed in such.

[steveforbes]

That is one of the most details and well done videos about this subject that I have seen. You demonstrate just how much manual labor is involved which most people do not realize is required. Excellent job!

[squeaky]

Finally a real world example. I’m watching this for it doesn’t have to be perfect perspective... thanks for showing how a guy in his garage could do it to help his vehicle rather than a perfect pro doing it at a shop!

[EastCoastMan]

Impressive work. I wish this guy was near me. Need more mechanics/body guys like this.

[spkay]

Very good, detailed rocker panel removal and replacement. Even used the flux welder which most DIY home mechanics most likely have.

[ericpigg]

Thanks for the info! You convinced me to let mine rot on!!!

[benjamindickey]

Don't ever leave primer without paint, most primers will soak up water and cause the metal to rust even faster

[kaybee]

I always use weld thru primer on the spot and butt welds. Especially underneath.

[frankt]

Great instructions. I think I should try this. Can’t hurt right. Thanks for the confidence boost.

[hillbillybu]

I bought the rockers from 1A for my ‘04 GMC Yukon XL. I was impressed with the panels. The gauge was heavier than the stock metal. This was my first time doing body panels and welding. I’ll do better on the opposite side because of what I’ve learned. (I forgot to spray the inner rocker before installing the panel). Thanks for this great video

[stephengroenenboom]

A very honest approach at this repair. Nice result and nice video

[jpauldion]

Just had this done - both rockers with new slip-ons from Ebay. The 2 panels were $135 and the labor by my own mechanic to cut out, replace, weld and bondo and prime was $1800. Not cheap but very necessary on my 24 year old Toyota Tundra!