TwinTurbo.NET: Nissan 300ZX forum - I have. Here's my process.
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Subject I have. Here's my process.
     
Posted by Goldchocobo on February 13, 2017 at 7:32 PM
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In Reply To Has anybody here repaired rusty rocker panels themselves? posted by BLACKTT3Z on February 13, 2017 at 02:53 PM
     
Message I have fixed many rockers with massive rust holes before. Repair turned out 10/10, can't tell the difference after the job.

Cut out rust holes with angle grinder

Grind off remaining rust bits on the inside.

Chemically treate surface rust on the inside of rockers, if any. I use either corrosion X, or Corroseal. Make sure to seal Corroseal with a good primer/paint after use!

Form some standard 20 gauge sheet metal to the approximate shape of holes you cut with hammer/vice. You can use the pieces of metal from the holes you cut as templates.

Tack in new metal with low power TIG. You can MIG it if you're a wizard, but too much heat will warp the panels.

Use bondo or bondo equivalent (I use Everclear) to re-form the shape to 100% accuracy. I would take it into a shop for this if you aren't confident with body work.

Repaint. Gotta go to a body shop for this. That, or use a good rattlecan rocker guard paint.

     
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