Tips on removing rocker box welds??
 

1971 blazer, I've unbolted the rocker box and reinforcement panel, now trying to figure out the best way to cut the welds holding the box to the support beam that runs front to back. Appears there are larger tack welds at every hole. Any pointers?

Re: Tips on removing rocker box welds??
 

make sure your top is on or braced.....

Then just rip apart with an angle grinder or reciprocating saw (second choice as this will vibrate and tear sheet metal) If not done right

not like you'll be using any of the rusty parts again

Dis reguard if you are doing a 100 point restoration, if so you will need to know location of spot welds

just think of it as a onion, keep removing bad layers, as you go

Re: Tips on removing rocker box welds??
 

It ain't easy but Jim has it right. I used a grinder, reciprocating saw, air hammer with a chisel, and just about every cuss word in the book getting mine off.

Good luck, Rg

Re: Tips on removing rocker box welds??
 

Plus the big mess on the floor, you'll have to clean up. I couldn't believe all the crap that came out

I came across a neat sheet metal tool for separating sheet metal, basically it's like a very thin chisel that you beat into the panels, BUT, I've lost the name of the company. They sold new and used tools from the aircraft assembly industry, if I find it I'll post up

Re: Tips on removing rocker box welds??
 

Thanks for the info. regarding the top front edge the of the rocker box, any way to access it to cut the welds other than removing the front fender and/or front inner wheel well?

Re: Tips on removing rocker box welds??
 

No, as far as I know, the bumper and fender has to come off...good luck with the bumper bolts, start soaking them now. While your in there, You might as well check out the lower 'A' pillar

Re: Tips on removing rocker box welds??
 

I removed my rocker box by cutting the metal around the spot welds and then grinding the metal and welds off the underside of the truck after that...

The front fender will need to come off if you are digging into it.

Also the comment about the top - completely agree to do that before you start and make sure the doors open and close like they should.

Have fun and take some pix of your project

Re: Tips on removing rocker box welds??
 

I was able to hack my way through it using reciprocating saw, cut off wheel, and as promised- a lot of time, dirt in the face, and cursing :). Accessed the front end welds by removing the front inner wheel well and turning the tire inward to make room. I know I will probably have to remove the fender eventually to get a good look at the lower A pillar, but trying to keep as much intact as possible to avoid frame shift. Doors and top still on also

Basically cut out small chunks at a time that seemed to open up new angles and openings for further cuts.

Re: Tips on removing rocker box welds??
 

Good job, I did one side at a time leaving the opposite fender, door, and radiator support bolted together. My theory was to leave the opposite side intact so the fender and door could act as a brace for the cowl along with the top. The rocker boxes were actually the last things I replaced (after the pillars and all other replacement metal). When I finished one side I reassembled the door and fender on it and removed the other side door and fender.

Good luck, Rg

Re: Tips on removing rocker box welds??
 

I used a carbide rotory bit with a quarter inch arbor on a die grinder to cut the weld near the the holes to aid the chisels ability .it came out damage free at the end of the day LOL