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backwoodsxj

Jeep XJ rock rails (door sill replacement)

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This is for NightPath to show how its done my way.There are other ways but this is very solid and will never move!This is stepsons XJ and was done Labor Day weekend and took me 2 days to complete and paint.

Before pic of good side of jeep both sides stoad in some from hard trails and rocks!

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Cutting them rockers off!

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Jacked tubing to testfit and measure finished length.We can get here local for $60 both sides 6 ft long and you have room to cut/trim both sides and cap the ends.

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We used angle iron also and we had this already for scrap.Billy cleaning up old weld and and shinning up to weld in.

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This is angle set up in place and welded in.It gives and solid place to lay your new rail and it allows for welding a great bead to body and rail.Also gives a nice flat bottom with floor.

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Rail up in place and welded in every four inches to angle iron and spotted every 2/3 inches to inner sill.Oh bottom of fender cut and tacked to rail also if you don't mind cutting?

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Seam seal all joints to keep out any water from creeping and it makes a clean job also once painted...

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I painted everything with rustpaint too to protect it....

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Finally I rock guarded the whole area for a pebbled finish.You could color match over this if you like and we planned to do white but he liked it black when he seen it....

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cheers!

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Great photos!

Interesting idea with the angle iron, have never seen it done like that before.

Yes the angle iron we had drilled holes in so that could be spot welded to inner side of old rocker which is usually pretty solid plus a nice bead across the top.It also allows you to pull the rectangular tubing in or out a bit to adjust to how much you want sticking out under doors as log as you have some left over angle to do your final weld and welding 3/16 to 3/16 is much stronger that just welding to old flange at bottom of rocker......

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Good thread! I used 2x6x3/16 tube and I think 3/16 x 1.5" flat bar

Cut out the rockers, clean tube and sills, tack up tube then tack flat bar from tube to floor to fill the gap behind the back edge of old rockers.

Stitch weld flat bar to floor and rail, weld solid rail to sill and then seal and paint

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This is a great thread! If I only had the fab skills.

Approximately what would a job like this cost me to get someone else to do it?

I have to be realistic in my fixes that need doing. It's rock sliders VS rocker panel but I DO have to take into account if the other rocker has rot (I believe it's good though), as well as needing new tires, brake pads + 1 caliper and the rot in the rear fender, plus my lift, so I have to balance it all out.

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It is threads like this that warrant having a "how it's done" sort of section in the tech forums B), so good how-to's don't get lost in the back pages of the section...

Good write-up Darren B)!!

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All years XJ. It is also a guide for doing the same thing on other rigs like Grand Cherokees and Libertys (eh, Tom ;)).

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It's a helluva sweet write up, that's for sure! Definitely going to go the extra little mile and get rock rails put in. Hopefully find someone that can do the rear drivers side inner fender repair as well.

I am going to have my kids riding with me, and rock rails might provide a extra bit of security when I'm out driving around.

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Toms and grands are a bit different we actually spilt the 2x6 into 2"x6" angle iron because of the bracing inside the rocker

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I thought that the rockers were going to be an issue. Took a solid look today and looks like the rot is just in the rocker, none in the floor pans, etc unless they are covered and hidden like a boss (I don't believe they are).

The rot around the rear fender flare / inner fender kind of got me concerned. Thats for another thread ;)

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Checked it out earlier with a friend. Floor, wheel well underneath looks very nice so I believe the rot I can see is what I have.

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Really to have that fixed or for parts your best place to ask where to buy them is a local body shop. There are a couple that I did a work term at in Greenwood, dont know if they are still there but can point you in the right direction.

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Took the XJ down tonight to get it looked at. Totally doable for the rock rails and rear quarter panel. Probably trim the rear panel and weld in a replacement for the inner fender to give the rear wheels more travel. Will have to figure out how to stick on some fender flares off of something to ensure I don't get stopped and can pass inspection lol.

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