1. Assess the Damage:
* Extent of Damage: Is it a small dent, a large dent, rust damage, or a hole? Pictures are helpful.
* Rust: Rust is a serious issue. Surface rust might be treatable, but deep rust often requires panel replacement.
* Structural Integrity: Is the rocker panel still structurally sound? Significant damage might compromise the vehicle's safety.
2. Repair Options:
* Paintless Dent Repair (PDR): For small dents without paint damage, PDR is the least invasive option. A skilled technician uses specialized tools to push the dent out from the inside. This avoids body filler and repainting.
* Body Filler and Repair: For larger dents or holes, this involves:
* Cleaning: Thoroughly clean and prepare the damaged area, removing rust and loose metal. Wire brushing, sanding, and possibly a rust converter are needed.
* Metal Repair (if necessary): For holes or significant damage, you may need to cut out the damaged section and weld in a new piece of metal. This requires welding skills and the correct replacement panel. A professional body shop is almost always necessary for this.
* Body Filler Application: Apply body filler in thin layers, allowing each layer to dry before applying the next. Sand smooth with progressively finer grit sandpaper.
* Priming and Painting: Apply a primer to seal the filler and then paint to match the vehicle's color. This usually needs professional-grade equipment and skills.
* Rocker Panel Replacement: For extensive rust damage or structural compromise, replacing the entire rocker panel is the best option. This is a significant job requiring welding, cutting, and body work expertise. This is almost always a professional job.
3. Tools and Materials (for minor repairs):
* Safety Glasses and Gloves: Essential for all repairs.
* Wire Brush: For cleaning rust.
* Rust Converter: Treats surface rust to prevent further spread.
* Sandpaper (various grits): For smoothing body filler.
* Body Filler: Choose a high-quality filler suitable for automotive repair.
* Primer: Use a high-quality automotive primer.
* Paint (matching the vehicle's color): Use automotive paint, preferably from a professional supplier who can match the color.
* Clear Coat: To protect the paint.
* Putty Knife: For applying body filler.
* Sanding Block: For even sanding.
* Masking Tape: To protect surrounding areas during painting.
4. When to Seek Professional Help:
* Extensive rust damage: Rust repair is complicated and requires expertise.
* Significant structural damage: Compromised structural integrity is a safety hazard.
* Welding is needed: Welding requires specific skills and equipment.
* Complex bodywork: Getting a professional, quality paint job is extremely difficult to replicate at home.
In summary: Unless you have experience in automotive body repair and welding, repairing a severely damaged rocker panel on a Ford Windstar is best left to professionals. For minor dents, PDR might be an option, but even then, consulting a professional body shop is recommended for assessment. Attempting significant repairs without the proper skills and equipment could lead to further damage and compromise the vehicle's safety.
