Rust Problem

Hello all I have a 94 cherokee 2 door. Both rocker panels are rusted through. I can find rocker panels for the four door but that is it. I was wondering the best way to fix the problem?

Thanks

[krabysniper]

Almost didnt bother to respond to this because this site has gotten so miserably slow (both in page loading/ and activity).

Anyway, in response to your dilema. IMO, the "best" way (for any XJ rocker panel repair) is to get some 2x3 1/8"wall boxed steel tubing, the length of each rocker, cut the rockers out from front wheel opening to rear so that the top edge of your tube rides flush along the bottom edge of door opening and set back "into" (so-to-speak) the old rocker area so that it isnt sticking way out, and welding into place all the way around and of course using weld thru primer and treating and painting the area afterwards to prevent further degradation. Also cap the ends of the tubes of course to keep moisture, mud, etc. out of the tube. (Added bonus is you can install bungs and fittings that would allow you to use them as air tanks, thus have an emergency tire filling source with you where ever you went) This will give you a cool "rock rail" that will effectively strengthen the chasis (greatly increases side impact protection for the passengers, and believe me it is needed in an XJ, I personaly have seen several after side impacts). Check out this one, granted this was after a semi hit it, but I have seen others with a simialar type of damage after being hit by a car.
http://tellico.off-road.com/wwwthrea...1217765-03.jpg
http://bbs.off-road.com/wwwthreads_u...1217763-02.jpg

If you can do the work yourself, I would say you should be able to pull it off for well under $300, if you go to a shop that is capable, probably in the nieghborhood of anywhere from $500-$1,000 give or take.

You could probably get a shop to do a hand formed patch panel repair for a lessor price, but you wouldn't get all the pluses you get doing it the way I have described. Just my thoughts on the matter.

[JohnnyV]

Here's a few links that krabysniper was talking about... saved links when I owned my XJ...sold it last year now driving a ZJ.

Tech Report - Extreme Duty Rocker Replacement

Extreme High-Clearance Rocker Panel Replacement

http://members.aon.at/jeep/projekt/schweller.htm

Box steel rocker panel conversion

4x4 Trail Hunters - Boxed in XJ Rockers

If you just want to replace:

Sherman Parts - Product List

Thank you for all of the info. It sounds like a good little project. I'm always looking for a reasion to tear into something.

buy the 4 door ones cut them and weld em in. jc whitney has em for $18