so over the past couple of years my 94 XJs has developed a severe case of rusty cancerous tumors on the rocker panels. I've always toyed with the idea of cutting them out putting some big rectangular tubing in their place to act as a replacements as well as to act rock sliders.  i finally decided it was time to do this 'mod' since i had some time on my hands (spring break).

first thing i did was take inventory of what kinds of material i had, fortunately i had accumulated a large quantity of steel through work and the only thing i had to order and purchase was the actual tubing i was going to use to fill the hole under my doors.  i went with 2x4 rectangular tubing.  it fills the gap quite nicely. 

the first thing that should be done is to get rid of the old rockers.  i used an angle grinder with a cut off wheel. it seemed to work reletively well.

i then went about measuring for all my cuts, (remember to always measure twice and cut once) this may not be the same for ever one and their own situation.  i used some angle iron for a majority of the structure and some plate to make flanges to where the sliders will mounted to the frame.  along with the flanges that mount to the frame i also use a piece of angle iron to attach to the pinch seam like many of the manufacturers have on their after market sliders

i then cut everything to length and drilled all the major holes needed. (again always measure twice and cut once) 

once everything was cut i moched all the peices into place to make sure everything fit properly.

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unfortunately i do not have a big enough welder to weld the material i had so i had to take my project to a friend of the family's to weld everything.

and here is the 'finished' product.  they still need to be painted and installed and i am thinking about cutting the front and rear of the 2x4 at an angle to make it 'flow' and look a little more professional.

hopefully i will be able to get them painted and installed before the cliffs run in april.

i planned on beveling the front and i didnt feel that the door frame and pinch seem alone would be strong enough, however like you said its held for 8 years so yet again i have learned something new, so if i ever have to do this again ill know and wont make so much work for my self.  thanks for the insight notoriuous

Post edited 4:03 pm – April 7, 2010 by jeepin_in_a_94

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so i was finally able to finish painting and installing my rocker/sliders and rear bumper over my easter break.

i used a wire brush/wheel on a drill to knock the big dirt and rust off i then prepped the entire area with acetone then used Loctite rust inhibitor to kinda coat the bigger rust spots to prevent any more bubbling. i then tapped everything off and painted the body with duplicolor rattle can bedliner.  i also painted my rear bumper and sliders with the bedliner.

this is my bro ty helping out

mrmikey32 said:

i think you should make another set and sell them to me

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haha i wish i had the time and resources to, its kinda hard when i go to schooll full time in Wisconsin and im only back home in IL.for some weekends and then summer time and when i am home and able to make this kind of stuff i neglect my girlfriend and family. and i dont have to proper tools like a nice big welder. also it was a real custom job like the dimensions would probly be way different for each jeep just because of the rust factor.

but it is my dream to open an off-road fab-shop, so its good to know people already like and want my 'products'