snopro700

Building some rockers for the ol XJ. Basic design credit actually goes to Bill McCarthy at SVE Performance of New Haven CT.

To start these are all bolt-in, no welding to the unibody will be done. This way I can drop them I I need to, but will remain plenty strong on the Jeep.

First I cut out what was left of the old rocker, a piece of 2x4 3/16 wall box fits in perfectly. Well, I wanted a little more side guard/step so I will be welding a second piece of 2x4 to it for a 2x8.

For mounting you can see the brackets I made up, they are 2" 3/16 angle, and each one will be bolted to the base of each pillar with 1/2" bolts. The pillar base is the strongest part of the unibody here and will be sufficient for a rocker, as well as further bracing the structure of the unibody together.

Later on they will be tied into the frame rail with boatsides, which will either be 1/8 steel or 3/16 aluminum plate, haven't decided on that yet. That will be accomplished by having each side bent on an angle thy will allow me to bolt to the bottom of the rocker, and the bottom of the frame rail, using countersunk bolts.

ArmyGuy

You don't think that the steel is just to thin? The size of the bolts is irrelevant, if the metal around it is thin (not even 1/8), then it might over stress it. Why not just weld them in? The material cost isn't that much.

snopro700

The steel is actually pretty thick there, if you look there multiple layers of steel spot welded together at the pillar base...Gotta figure that they had to make it strong enough to withstand a roll over without having the pillars fail completely and crush occupants.

Also with the number of bolts I'm using tied into all 3 pillars it will spread the load evenly. Don't forget they will also be tied directly into the frame rails eventually as well.

Yes they could have been welded, but bolted can be just as strong, and I want to be able to remove them if I have to.

PocketsEmpty

Subbed. Interested to see how the bolt-in job turns out. Pics of the cut out rocker?

HS00XJ

subscribed

snopro700

Quick mock up so you guys got an idea of how I cut and how it will mount.























Obviously all said and done it will tuck up flush with the cut and they will sit inward a little farther...this was just a quicki for some
Pics...won't be working on it much tonight due to school. But hoping to be done by the end of the weekend.

PocketsEmpty

Interesting. How are you going to attach it from underneath?

snopro700

I will be making sort of a boatside for it...will bend up a piece of plate steel in the brake at our sheetmetal shop...it will be bolted to the bottom of the inner 2x4, come down on and angle, and then be bent level again to tie into the bottom of the frame rail. That will all be held together with countersunk bolts for a nice smooth sliding surface.

kal1fornia

Awesome! Can't wait to see how this thing turns out!!

rctrav

Your definitely thinking out side the box. But why do you feel the need to bolt them on and take them off when need be? Just weld them up and be done with it.

snopro700

Because rust, I wanna be able to clean out and repaint under there if I have to. Also, welding 3/16 to the existing metal is a PITA. Bolted will be just as strong. I've seen guys bounce their XJs off rocks with these for years and the rockers and unibody are still straight.

JeepMN

Just bedline it lol

ArmyGuy

I used a undercoat wand to shoot stuff inside my 2x5 rocker, and then will use wands with fluid film for the inner rocker area. I painted everything before I put it in there but I doubt rust would become an issue doing it like that.

snopro700

If you've seen my Jeep you'd understand lol. I got a lot more work to do on rust, it's just easier to be able to take the rockers off when I get to it. I just need the unibody bracing and armor asap.

Also getting the front fender off would be an issue with the rockers in the way. since I plan on bringing the outer 2x4 all the way up to the fender flare.

Don't know why everyone seems to be so stuck to "weld the ****er on." I know this is a proven design, I've seen it work. and really, once the brackets are in place it's a lot less work than welding. just drilling some holes and running a tap through.

snopro700

Bedliner IMO can be worse, it can trap moisture in and really cause problems down the road.