Body panels replacement

[Jakedog]

I need to replace the driver side lower quarter panel, the rocker panel, and the B pillar. This is my first time doing something like this.
My question is, in what order should they be replaced once everything is removed?

It seems pretty straightforward when I look at how they overlap, but I'd like some advice from those who have done this.

Thanks.

 

[Torkman66]

The most important and often biggest mistake is getting the B pillar back into the right location. It sets the placement of the rocker, rear quarter, and importantly the door gaps. There are lots of ways of doing it and any will work with the right prep and measurement checking. Take very detailed measurements of door opening. Consider placing rocker in first with door on and gaps all adjusted before final welds. Use a lot of self-tapping screws to hold things in place before welding so you can ENSURE everything is aligned perfect before you weld. The B pillar sets everything in place, so it is very important to get perfect.
Post pics.

 

[jamesroney]

I need to replace the driver side lower quarter panel, the rocker panel, and the B pillar. This is my first time doing something like this.
My question is, in what order should they be replaced once everything is removed?

It seems pretty straightforward when I look at how they overlap, but I'd like some advice from those who have done this.

Thanks.

You are super lucky! Your Bronco is still together...so you can take measurements before you take it apart! As @Torkman66 says...the most important thing is to get the B-post in the right location. But what he DIDN'T say was where the right location actually is.

There are two choices:
1. Put the B-post back exactly where Ford put it on at the factory.
2. Put the B-post on exactly where Ford should have put it on at the factory.

Many Broncos are built wrong from the factory, and the passenger side is longer than the driver. So the door gaps are bigger on the passenger side. If you build it with the "correct" door gaps, then the fender ends up short at the grill...and the hood ends up "too long."

Note that you can't install the rocker the way the factory did. The pinch weld between the rocker and lower rear quarter (about 4 inches) has to happen before the panels are installed. You can't weld it from the front...because the rocker is in the way. And you can't weld if from the rear because the b-post flange is in the way. I have come to the conclusion that it is impossible to assemble correctly without a jig. But there is a cheat, and you can drill access holess in the B-post flange and then plug weld the rocker to the quarter thru the access holes. Then you can weld the access holes. it's only about 4 spot welds but you will drive yourself crazy trying to reach them.

 

[AZ73]

Note that if you are using an after market B pillar, even one claiming to be "factory stamped", it's not going to be exactly the same dimensions. While I didn't do the B pillar, I did my "A" pillar door post and it was 3/4" taller and my outer rockers were 1/2" longer. I had to trim down the top of the Door post and re-bend the front of the outer rocker to get it perfect. The bend was not super clean but I ran a welding bead along the edge and filed it perfect (you can see the bead in the third picture before filing.) I suggest you drill out the spot welds (Harbor freight's spot weld drill bit works great) Then take your new B piller, hold it in place to line it up with C clamp vice grips, and see how it works. When you think you got it correct, use maybe 6 #10 hex head self drilling sheet metal screws to hold it in place, and try lining up the door. Do the same with the rocker. Hint: I painted the inside of the rocker to prevent future rust - remember, zinc based primer gives off a poisonous gas when you weld it so wear a respirator if you do this. I used KBS epoxy on the metal, but weldable primer where the spot welds would go. If it all lines up, pull out one screw at a time and weld the holes up, then finish spot welding. This is very simplified, but hopefully you get the idea. Good luck! It's very rewarding when you're finished. I didn't take a lot of pictures but here's a few:

 

[Jakedog]

I need to replace the driver side lower quarter panel, the rocker panel, and the B pillar. This is my first time doing something like this.
My question is, in what order should they be replaced once everything is removed?

It seems pretty straightforward when I look at how they overlap, but I'd like some advice from those who have done this.

Thanks.

Thanks for all the advice.
I wish I would have taken pictures of the B pillar and rocker after I purchased the Bronco.
At some point in it's life it rolled on to it's left side.
Who ever repaired it welded the strike plate to the B pillar, and fiber glassed the top of the rocker.
Shitty work at best.