1. Assessment and Preparation:
* Damage Assessment: Thoroughly inspect the extent of the rust or damage. Is it just surface rust, or is the metal severely compromised? Determine how much of the rocker panel needs replacement. Sometimes, patching is possible, but often a full replacement is necessary.
* Parts Sourcing: Find a replacement rocker panel. These are sometimes available from classic car parts suppliers, or you might need to find a donor car. Consider the quality – reproduction panels may require more fitting and adjustment than original parts.
* Tools and Materials: You'll need a variety of tools including:
* Welding equipment (MIG welder is recommended): This is crucial for attaching the new panel.
* Grinder with cutting and grinding wheels: For removing the old rocker panel.
* Metal shears or cutoff wheel: To cut the new panel to size if necessary.
* Hammer and dolly: For shaping and aligning the metal.
* Welding gloves, safety glasses, and respirator: Essential safety gear.
* Measuring tape and ruler: For accurate measurements.
* Body filler (Bondo): To smooth out imperfections after welding.
* Primer and paint: To finish the repair.
* Seam sealer: To prevent rust and improve sealing.
* Jack stands and safety stands: To support the car safely while working underneath.
2. Removal of the Old Rocker Panel:
* Prepare the area: Clean the area thoroughly to remove dirt, debris, and loose rust.
* Cut out the damaged section: Carefully cut away the rusted or damaged section of the rocker panel using a grinder with a cutting wheel. Try to cut along the seams to create clean edges for welding.
* Remove any remaining parts: This may involve removing interior trim, door sills, and other components that could interfere with the welding process.
3. Installation of the New Rocker Panel:
* Fitting the new panel: This is often the most challenging part. The new panel will likely need to be carefully shaped and fitted to the existing bodywork. You may need to use a hammer and dolly to carefully align and bend the metal to match the contours of the car.
* Welding: Tack weld the new rocker panel in place at several points to ensure a secure fit before completing the welds. Use proper welding techniques to avoid burning through the metal. Take your time and make sure the welds are strong and even.
* Grinding and shaping: After welding, grind down the welds to create a smooth surface. Fill any imperfections with body filler and sand smooth.
4. Finishing:
* Primer: Apply a coat of automotive primer to the repaired area.
* Paint: Match the paint color as closely as possible and apply multiple coats, sanding between coats for a smooth finish.
* Seam sealer: Apply seam sealer along all the welds and seams to prevent future rust.
* Reassembly: Reinstall any removed interior trim or components.
Important Considerations:
* Rust Repair: If extensive rust is present, address it aggressively. This may involve treating the entire area with a rust converter or other rust prevention products.
* Structural Integrity: Rocker panels are structural components. Ensure the new panel is properly welded and aligned to maintain the structural integrity of the car.
* Professional Help: If you lack experience with welding and body repair, consider taking the car to a professional body shop. A poorly executed repair can lead to more problems down the line.
This is a general overview. A detailed, step-by-step guide with pictures would be much more helpful. Searching YouTube for "1972 Chevy Nova rocker panel replacement" will provide video tutorials that can be invaluable. Remember safety first throughout the entire process.
