1. Assess the Damage:
* Rust: This is a common problem with older Tauruses. Determine the extent of the rust. Surface rust might be manageable, but significant rust-through will require more extensive work.
* Dents: How deep and widespread are the dents? Small dents might be fixable with PDR (Paintless Dent Repair), while larger ones will need more involved bodywork.
* Holes: Are there any holes in the rocker panel? This dramatically increases the complexity of the repair.
* Structural Damage: Is the rocker panel's structural integrity compromised? This is crucial – if the structural integrity is significantly damaged, you might need a replacement panel rather than just a repair.
2. Repair Methods (depending on damage):
* Minor Dents & Surface Rust:
* Cleaning: Thoroughly clean the area with a wire brush, degreaser, and rust converter.
* PDR (Paintless Dent Repair): A professional can often remove minor dents without body filler.
* Rust Treatment: Apply a rust converter to neutralize the rust and prevent further spread. Follow the product instructions carefully.
* Primer & Paint: Prime and paint the repaired area to match the car's original color.
* Moderate Dents & Rust:
* Cleaning: As above.
* Rust Repair: Cut out any severely rusted areas. Use a rust-resistant metal patch (often steel or aluminum) to replace the damaged sections. Welding is usually necessary for this, requiring skill and proper equipment.
* Body Filler: Apply body filler to smooth out the repaired area. Sand it down carefully and evenly. Multiple coats might be necessary.
* Primer & Paint: Prime and paint as above.
* Severe Rust & Structural Damage:
* Replacement: This is the most involved repair. You'll likely need to purchase a replacement rocker panel. This is often challenging to find for older cars. You'll need to cut out the severely damaged section and weld in the replacement panel. This is a very advanced repair requiring significant welding and bodywork skills.
* Professional Help: For severe damage, taking the car to a professional body shop is highly recommended.
3. Tools & Materials (General):
* Wire brush
* Degreaser
* Rust converter
* Rust-resistant metal patch (if needed)
* Welding equipment (if needed; MIG welder is commonly used)
* Body filler
* Sandpaper (various grits)
* Primer
* Automotive paint (matching the car's color)
* Clear coat
* Safety glasses
* Respirator
* Gloves
4. Important Considerations:
* Safety: Welding is dangerous. If you're not experienced in welding, do not attempt it.
* Professional Help: If you're unsure about any step, consult a professional body shop. Repairing rocker panels correctly is crucial for the car's structural integrity and safety.
* Parts Availability: Finding replacement rocker panels for a 1997 Ford Taurus might be challenging. You might need to search online automotive parts suppliers or salvage yards.
In short, repairing rocker panels can range from a relatively simple DIY project to a complex job best left to professionals. The extent of the damage dictates the approach. Always prioritize safety and consider seeking professional help if you lack the necessary skills or tools.
