Rocker Panel Removal – MX5 Miata Rust Repair Pt. 3 – Underdog Garage

Rocker Panel Removal – MX5 Miata Rust Repair Pt. 3 – Underdog Garage

Hey, what’s up, this is Pete. Welcome back to underdog garage
We’re getting into part three of this Miata rust repair series where we’re actually going to be taking out the main
structural rocker panel of our Miata
so we have a lot of work ahead of us a lot of cutting a lot of grinding a lot of plug weld drilling and
Just a ton of work to get this thing out
But I’m super excited to get into it and share it with you and see what we find
So with that said, let’s go ahead and tackle this rocker panel
I’m going to mark all the spot welds on the rocker panel with a paint pen. So they’re easier to identify what I’m drilling
Using an angle grinder, I’m removing the paint to make the spot welds easier to see
I’m scraping off most of the sealant around the rocker panel while I may not be directly
welding in that area the melting sealant from the heat smells awful and I will reseal it after I will
Okay, after marking all of the plug welds with paint pen
I found that I have a T plug loads
So I have a lot of drilling ahead of me
But the plan is I’m going to tackle the plug welds on the underside of the panel of the rocker panel
First won’t bore you with a lot of the details, but I’ll check in with you after I finish plug weld number 80
I started off tackling some of the spot welds on the other side
The rocker panel rust made them tough to cut and see but I would drill a bit then pry a bit separate the panels
Until it finally started
It was a plug well drilling marathon
The moment you think you have all of them drilled out you have 20 more lined up waiting for you ready to be drilled
After finishing up on the underside and it was time to tackle the spot well from the top of the camera
These were all pretty accessible and easy to drill out
As we were drilling out spot-welds we take a moment and start separating the panel from the inner structure
To get a better understanding of the structure of the rocker panel
I cut into the center where I knew there wasn’t any interior metal that I could risk cutting into
Now that we had a better idea of what was inside the rocker panel we decided to cut out a big chunk of the center
To give us more access
So we could see exactly what’s in there
Now I’m removing the remaining part of the underside of the rocker panel
This was the most difficult as this was the most voted and rusty
Lots of hammering and prying till it finally came free
Now all that was remaining was the front corner that sits behind the fender panel
It’s very satisfying pulling rusty metal off a car knowing that you’re going to put good even better metal back in
With that final piece remove this rocker panel is pretty much gone
Now I’m ready to clean and prep the area for when we go in to weld the new rocker meal
All right, so you can see we’ve gotten our main rocker panel off the car now
Super exciting big step in this project and I’m happy that we’ve gotten to this point
I have a lot of work to do still have to patch in some areas on the inside of the the rocker and
Get those fixed before we can put the new panel in
I was actually kind of surprised at how much the rust had drifted into the center of the panel
It’s kind of amazing how much rust travels especially in
Really high moisture areas, and it’s amazing that it can kind of travel without you really knowing it
but we’ll get that all cleaned up and get that straight now and
We’ll be ready for the new panel. All right, that’s it for this episode
Thanks so much for watching make sure to subscribe so you don’t miss any future episodes coming up
You can also hit us up on Facebook and Instagram at underdog garage. So we appreciate you watching and we will see you next time

3 Replies to “Rocker Panel Removal – MX5 Miata Rust Repair Pt. 3 – Underdog Garage”

  1. "It's amazing how much rust travels" – on these cars the rockers literally fill with water and you can hear it sloshing around inside the rocker if you haven't pulled the drain plugs.

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