I have a 97 F-150 Super Cab that is rusting around the rocker panels more so on the drivers side is there a fix for without having the body shop replace the panels?

 

My truck has no rust at all but if I were to have to repair it, I would grind the rust away and then fiberglass the area, sand, fill, prime, and paint.
The natural enemy of rust is fiberglass and it is a structural material that adds strength to the area. Cutting out the rust and then welding a steel patch works too, but in my experience that is a lot more work than the fibergalss repair and steel may rust again.

 

Just remember, fiberglass is not as strong as steel, and the rocker panel is a place where I would want some structural integrity if in an accident. (though I'm not an engineer)

That said, it really depends on how early you caught the rust, if its just surface rust, then prep it reallllllllllly well, add some rust inhibitor, some body filler or glass, and paint.

Rust can be cancerous though, and is extremely hard to get rid of, alot of times it is like mold and can only be completely gotten rid of by cutting out. If you're going to try and save it, use a buffing wheel until you've gotten all of the rust, then change to a new buffing wheel and buff it some more. I can't emphasize enough to change buffing wheels and routinely grab a new piece of sandpaper. If you're buffing or sanding with a wheel that has even a particle of rust on it (once you think you've gotten it clean) you're wasting your time.

 

Now if you are really lazy, you do like a friend of mine did. He cut out all the rusted area and stuffed crushed aluminum soda cans in the rocker area hole, then spread a gallon of bondo over the cavity and sanded it smooth. It will never rust again in that area, I guarantee you that.

 

I was told there is a spray that can be bought and sprayed on the rust and will make it possible to paint over..Is this true?

 

All your doing by cleaning and fiberglassing, or bondo, is buying a little time. Very little. By the time you notice the rust bubbling the paint, the insides are completely rusted through. Poke at the bubbly section, and your finger will go through.
Only way to fix them right is to cut out any rust to good metal, clean and paint everything possible, and install new steel.

Heres what they look like from the inside. They looked like simple surface rust untill I knocked the holes in them.
To get to good metal, I would have had to cut the complete bottom out of them. Easier to replace the whole thing.

 

instead of just using paint after you have it the way you want it i would go and get some rubber compound undercoating. thats what i am doing with my whole frame right now
it is thicker and well last longer than paint

 

Skizriz, where did you get your rockers, and how much were they?

 

Got them from a place just south of Pittsburgh. Parker Metal Products.
They were $135 each for the Screw.
The website isn't very current, give them a call if what you want isn't listed.
http://www.pmpautoparts.net/

There's also a place in Ohio,Lake Erie Trading Post. The prices are about the same.
http://www.fixmyrust.com/

 

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