I plant to remove rusted rocker panel and replace with slip-on cover panels. I am thinking if I use panel adhesive instead of welding, I can ensure primer and paint remains on all sides and edges of panels remain vs being burned off with a welder - thus providing better rust prevention. plus I never welded or own a welder so there is also that benefit. Thoughts and opinions appreciated on my theory of attack

 

Many new vehicles are being designed & built with adhesive instead of welding, because it's MUCH stronger than spot-welding, and it seals the joint in 1 operation, and for the reasons you mentioned. JBWeld is an option for small jobs.

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I used pl premium years ago on an old 88 aerostar I had...that was back in the 90s....I would think by now with the newer adhesives it will outlast the panel....lol

 

I would say no until I found out the whole tail section of passenger Jets are held on with only an adhesive. Much stronger than rivets

 

My rockers aren't totally rotted so my plan is to clean up the holes and go with the no-weld.

My old school body guy said the kids entering the industry are more likely schooled on adhesive over welding.

 

These new metal adhesives are great, used them myself.
Make sure the metal is bare and gone over with at least 330 grit sandpaper then cleaned squeaky clean with either 97% rubbing alcohol, acetone or lacquer thinner .
However not 100% totally trusting adhesives alone i've always used a few small sheet metal stainless screws strategically placed as insurance.

 

If you use something volatile, you have to be careful of condensation on the metal before the adhesive is applied. It doesn't take much to compromise the bond. I wouldn't use a torch right after a solvent, but SOME heat is needed drive off the last reside & humidity.

 

I somewhat agree a torch might leave combustible artifacts on the work if the heat is applied directly on the surface to be adhesive'd.
97% rubbing aclohol, acetone and lacquer thinner evaporate pretty dam quick but as any solvent evaporate they have a cooling effect attracting condensation depending on the ambient temperature.

A torch if used correctly on the 'under side' of the metal to be adhesive'd could work if used lightly just enough to evaporate any condensation.
If condensation is present after wiping clean with a solvent, i've been known to use an incandescent heat or flood lamp to further evaporate any moisture or lingering solvent off.

When applying any kind of adhesive trust me, it pays to be **** for the long term integrity of the bond.

 

When we rebuilt my 05 back in 2009 we bonded the bedside in instead of welding and when I sold it ten years later it was still holding tight and not rusted. Glueing works.

 

A torch leaves no residue (unless it's making soot). The danger is the FLAME setting fire to the solvent residue.