[wrpii]

I have not been able to find the rocker panels to replace mine. They have finally rusted out, especially bad at the jack points. Does anyone have any suggestions. Bought the car new while in the Army in Germany and it is otherwise in GREAT shape(230K miles).

 

[mxfrank]

I welded patches into the jack points. Patches were made from mild steel sheets. I installed the plastic rocker covers from a later car, which gives it a nice finished look. The one thing I have to warn you about is that the car rusts from the inside out. If you get into it, you may find that the rust you see is the tip of the iceberg.

190 Restoration

 

[wrpii]

Thanks for the quick reply. Your point is well taken, however I can not detect any other problems. The engine is fine (42 mph !) and I've been diligent in preventative maintenance. It will really sadden me to get rid of it. I do not however want to risk safety and the rocker does seem to be a structurally integral part. If you could provide more details about your fix, "patches in the jack points" I would appreciate it. I have found a garage that is willing to do a "functional" repair, and some advice as to what worked for you would help.
Thanks again

 

[mxfrank]

If you have some basic metalworking skills, it's not too hard. Just cut until you have clean metal. If you want to retain the original contour, use a hammer and dolly to create a concave patch. Otherwise, just roll a piece of steel to match to general curve, cut it to match the hole and weld. The only trick if you do this is to extend the jack tubes, which is easily done by welding a piece of 1" plumbing to the end of the existing tube. As long as the welds are reasonably good, strength will be preserved.

One thing I would suggest is to never weld OVER the existing metal. While it may seem that two layers of steel are stronger than one, that's not the case.

 

[sailtough]

As pointed out above, beware the rust you can not see. My 1987 190DT's spring perch rusted out spontaneously spitting the left front spring onto the road. Throw the car up on a lift and inspect before going any further. Wish I had.

J

 

[Stretch]

In America Klokkerholm panels are available at fix my rust

(This is not a recommendation - I don't think Klokkerholm put in enough effort into making their panels - you are better off buying dealer items if you can afford them)