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GA_Scout - Project: Tube Rockers and New Floors
Started with this 1979 Scout II
Passenger Side Floor 
Passenger Side Floor - PO patch panels removed 
Passenger Side Floor - PO patch panels removed 
I love the road sign patch panel mounted with self tapping screws. The PO also installed new outer rockers, but put them over the old ones and installed with self tapping screws. This just casued more rust and I am not reusing them. 
Drivers Side Floor 
Driver Side Floor - PO patch panels removed 
Driver Side Floor - PO patch panels removed 
Driver Side Floor - PO patch panels removed 
Rear Cargo Area- Yeah, that's also a very large road sign 
Rear Cargo Area - PO patch panel removed 
Rear Cargo Area - PO patch panel removed 
Front fenders removed - The truck has been sitting for a few years and it looks like someone made a home in there. I filled up my shop vac 5 times with rat poo and rat nests. They were everywhere. 
Getting the floor cut out 
Rocker removed 
I know that some of this is kind of heavy, but it was free. I have a friend that used to own a fab shop and he has tons of metal that he is no longer using. The metal being free does sway some of my solutions. I will be replacing the full length of the rockers with 2.5 x 2.5 1/4 wall square tube. The rockers will be supported by 1.5 x 1.5 3/16 wall square tube welded to the frame. The front body mounts are in bad shape. I really don't think I will need them because of the way I am doing the above. I will be replacing the front floors, up to the floor seem, with 14ga sheetmetal. I will also need a few small patches here and there. I will also be replacing the entire cargo area with 14ga sheetmetal. I did a little cleaning to the frame, got the rest of the rocker removed, and got the new rocker mocked up last night. The picture below is the concept that I have for the supports. Red = 2.5 x 2.5 1/4 wall square tube for rocker White = 1.5 x 1.5 3/16 wall square tube for rocker support Blue = 3/4 angle or square tube for floor support The front body mounts are in bad shape and the rear aren't much better. I really don't think I will need them because of the way I am doing the above. Also, does anyone know where the D&C Cage enters the floor. I was thinking that I could tie the cage into the front and rear rocker supports. 
Getting the rocker mocked up 
Welded in with four supports 
Before 
After 
Got a little done, despite the fact that I ran out of gas for the welder and had to spend a couple hours to track some down. And no making fun of my welds. I had it a little hot and had to fill in a couple burn throughs. Oh well, the floor will cover it. The structural welds on the thick stuff looks good. Floor supports in and a few patches made 
One more patch in the rear and a little grinding and cleanup to do, then in with the floors. Rear Patch 
Floor Installed 
Floor Installed 
I had to cut about an inch off the bottom of the fenders 
It was rusty anyway 
Fender is ready and I got the door back on. It fits just like it did before I started, terrible. Not too bad really, the gaps are just a little large. It looks like I will add about an inch to the bottom of the door to get it to line up with the bottom of the rocker. Tomorrow I will start on the doglegs, bottom seal, and the door. Fender and Door on 
I got the doglegs, bottom seal, and patch on the back corner made and welded up. I then sealed all the seems and put a coat of primer on. 
Now I have to patch the quarter and add to the bottom of the door. That should be it for this side. I have been busy lately, but finally found some time to work on the scout. It is amazing how much faster this side is going after I have already done it once. 
Rocker Removed 
Floors and supports removed and frame cleaned up. 
A little sawzall action 
New Rocker Welded Up 
More Rust 
Used the angle grinder this time. Look at that nasty IH oil pan in the background!!!! 
Patch Welded In 
Patch Started 
Ready for floors 
Floor in 
Patch made 
All Done 
Now I have to install the fender, trim the door down, and re-install the door. Then, it is on to the cargo area. I ordered some new wheelwells for a 73-87 GM Pickup to replace my rusty ones and give me some added area to stuff the 36s into. That is the best $20 I have ever spent - Kobalt Air Hammer. 
What a mess! 
And a couple hours later 
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