My pleasure Vince. I have wanted to post everything I have learned from this project for a long time now and just haven't found the time. Thanks for the motivation. A long time ago I was lucky enough to find a thread username Lysander put together over at ClubGP. It helped me immensely. I have never done a project like this before so his pics and details were very useful. He did an amazing job on his. I tried finding his old thread, but ClubGp is no more. As luck would have it I stumble upon this thread he put together over at Autobody101.com. Anyone tackling this project should check it out....
1997 Pontiac Grand Prix rocker panel fix - Update, painted! • How to Paint Your Own Car, Auto Body Discussion Forum & Videos • AutoBody101.com
The next thing I should mention about my project has to do with the lower section of the door hinge pillar that intersects with the rocker. I didn't get a good pic of mine before I disassembled it but this pic from Lysnader's post shows what this section should look like before the outer rocker panel is installed.
Here's a pic of my rotted hinge pillar mocked up with my new rocker reinforcement. This should give you a sense of what I'm referring to.
The hinge pillar is 14 gauge steel and quite a complex piece. I tried forming a new one from some 14 gauge sheet and it was impossible with my limited tools. I could have made it in sections and welded them, but it would have take me quite a bit of time. Then I discovered I could purchase the entire hinge pillar for just $120. My time is worth that so I bought the part. It's the whole hinge pillar and the windshield post, but I only need the lower section.
Here's my rotted piece over the new part.
