PSA: I chose to weld a new rocker panel section instead of using a full replacement panel on a 2008 Silverado

The customer wanted the cheapest fix, but the full panel was $400 and a 12-hour job. I cut out just the rusted part, about 18 inches long, and welded in a patch I formed myself. It took me 6 hours total and saved the customer half the cost. The fit was perfect and the repair has held for over a year now. When do you guys decide to patch versus replace a whole panel?

3 comments

3 Comments

patricia421mo ago

Patching done right lasts just as long.

the_ben1mo ago

Patching rust is just kicking the can down the road. You saved money now, but that seam is a perfect spot for moisture and salt to hide and start rusting again from the inside. A full panel replacement gets rid of all the compromised metal, which is the only real fix for a structural area like a rocker. The extra labor cost is for a repair that lasts the life of the truck, not just another year or two.

victor_davis171mo ago

My old truck is basically a patchwork quilt of rust repairs at this point. Guess I'm the king of kicking that can down the road. It's a miracle the doors still shut.