Rusty FJ-60 rocker panel/lower rear quarter removal and replacement ideas...

[Zack1978]

Hi everyone,
In an attempt to practice my body work skills and use my welder I would like to remove and replace the rusty rocker panels and lower rear quarters (quarter chop?) on my 1987 FJ-60. I know that I could get used panels an attempt to weld them in. That might be what I end up doing, but what other options do I have?
I know that many people have removed the rocker panels all together and used steel tube. Does anyone have specific plans for that, ie, materials used, etc? How difficult is the job of removing the rockers? Where would you weld the steel tube to? I don't do any off-roading, so I am not looking for sliders. This job would be practice. What about the quarter chop, how is that done?
Any and all help would be appreciated!

Thanks,
Zack

 

[Mace]

The 1/4 chop is basically just removing metal. You do not really have to add anything back in there.

I have 2x3 sliders because I wanted to open the doors after a day's worth of wheeling.

 

[BennyBoy]

The 1/4 chop is basically just removing metal. You do not really have to add anything back in there.

I have 2x3 sliders because I wanted to open the doors after a day's worth of wheeling.

So you just leave the inner and outer panels unattached? Sounds hokey to me. Mine are all rusted out and I get a lot of noise through there.

 

[lehiguy]

I cut off the lower portion of my rear quarters and used aluminum angle and plate to patch it back up. The joints are a combination of rivets and seam seal. I used DIY bedliner on the finished product.

 

[Mace]

I was actually referring to the rockers. Yrs you have to fill in the rear quarters. Rockers can just be trimmed