Building rock rails

[admin]

Everyone likes pics, right? Here are some of my rock rails I finally got to work on last night. This is step 26 in my ongoing effort to get my '72 ready for paint. %)

I won't go into too much detail since several people on the forums have already done this, but if you have questions feel free to ask.

More pics here: http://classicbroncos.com/photos/showgallery.php/cat/6375

 

[admin]

The steel is 2"x6". I almost got 2"x5" because I was worried it would stick out too far. But now that I have my new War Flares on the 6" looks perfect.

 

[mp]

Looks good! I am doing the exact same set up and have everything cut out ready to weld in. I went with 2x6 also.

 

[Tito]

Looks excellent! I am trying to decide on width with mine too. I am running the gorillas so I might do 4x4 with tubes out. I do like the look of how you have done it though.

 

[SC74]

It won't be long and I'll be working on mine also - the pics give me a good direction to start in. I like the way the 2x6 sticks out too. What wall thickness are you using - looks like .120? How are you going to tie it into the frame?

 

[73ny]

Are you going to cap the ends?

 

[admin]

What wall thickness are you using - looks like .120? How are you going to tie it into the frame?

Good eye. Yes, it's .120. I was going to go w/ 3/16" but when I got to the steel yard it just looked way too beefy.

I'm not going to tie them into the frame. I'm welding to the body. I'm pretty confident the load will be spread out sufficiently to not cause damage. I'll post back with trail carnage pics if I'm wrong.

Are you going to cap the ends?

Yes. I haven't cut the ends yet. They'll be angled to match the flares. (lines drawn in the pics)

 

[admin]

Looks good! I am doing the exact same set up and have everything cut out ready to weld in. I went with 2x6 also.

Did you cut below the door sill in the same place I did? What are you using between the top of the 2x6 and the sill? I'm planning on going w/ some 3/4" stock.

 

[SC74]

I'm welding to the body. I'm pretty confident the load will be spread out sufficiently to not cause damage. I'll post back with trail carnage pics if I'm wrong.

My wife's rig has BC's rocker gaurds and it is the same principle - spread the load. They've seen some rock rash and I've used them for a high-lift jack lift point before with no problems.

 

[Dan74Bronc]

Rock rail

I like the look of the 2x6 tube. I went with the 3x3 just because that's what I had handy. I cut the old rocker off about 1/2 inch below the door sill bend and put the square tube up against the body on the inside if the sheetmetal 1/2 " lip. Worked for me but the front fender didn't fit well. I cut the bottom off the front fender and welded a 1" piece along the bottom and bolted the fender to the rock ski. I added a nerf bar later just because. Pictures are worth a thousand words.

 

[Doyle]

Looks like mine. I did use the 3/16" wall tube. I capped the ends with 1/4" on an angle to match the flares. Very solid, you can jack the whole side of the Bronc up using these.

 

[mustangtoby]

Wow! My rockers aren't in the greatest shape, and I was thinking of doing somthing along these lines. This is great info. If a guy wanted to get really creative you could do a half assed exo-cage from these to tie into the bumpers, outlining the wheelwells. Might look kinda funky, but would really help protect the sides when serious rockcrawling.

 

[76MaBronco]

Jon,

Looks good...you might want to add a couple 1 x 2 jack studs just so it touches the frame with a rubber pad between...just in case the truck slides down a rock and comes to rest on the rocker. This will use the frame as an extra support while not being attached to it. Just a thought.

 

[RedLeg0811]

bronko69er, did his with 4x6 tube and capped the ends. The reason he went with 4x6 was to make them into air tanks. I can't remember the thickness.

I want to do something like that, but I am torn as my rocker panels look good. At least for right now.

Martin

 

[joser]

I did the same mod this Summer.

I used 3/16" 2X6 box. I did not tie into frame. I also cut my old rockers about 1/2" below door sill. I did not put anything inbetween the sill and rock ski. Hardest part I thought was welding the backside of the sheet metal to the rock ski. Here's a pic of mine finished.

Jon - You going to test those at this year's Stampede? Almost no better place to test recent mods than the Flo Jct area.

 

[Mherriford]

Hey Jon I think that your drivers seat may need adjusted

 

[mp]

Did you cut below the door sill in the same place I did? What are you using between the top of the 2x6 and the sill? I'm planning on going w/ some 3/4" stock.

I wound up with some angle iron after looking at my options. Found some aluminum, but the stock wound up costing more than $100! 3/4 was too thick and left a gap. I am going to run a strip of the angle iron centered in the sill welded to the top of the 2x6 like a teepee. It is the perfect heighth and should provide the support needed to keep the sill from caving in.

 

[regshawn]

I like the look of the 2x6 tube. I went with the 3x3 just because that's what I had handy. I cut the old rocker off about 1/2 inch below the door sill bend and put the square tube up against the body on the inside if the sheet metal 1/2 " lip. Worked for me but the front fender didn't fit well. I cut the bottom off the front fender and welded a 1" piece along the bottom and bolted the fender to the rock ski. I added a Nerf bar later just because. Pictures are worth a thousand words.

That is a nice look, and that was just what I had planned to do. I do how ever need to make friends with someone with a tubing bender! Once painted you would really have to look to tell that was not a rocker.
Did you tie it to the frame?
Shawn

 

[Amac70]

That is a nice look, and that was just what I had planned to do. I do how ever need to make friends with someone with a tubing bender! Once painted you would really have to look to tell that was not a rocker.
Did you tie it to the frame?
Shawn

well i guy with a tubing bender needs to make freinds with a guy that can cut glass.

 

[regshawn]

well i guy with a tubing bender needs to make Friends with a guy that can cut glass.

Well I can cut the Shi.....crap out of glass, just need to find and be-friend a guy with the tubing bender!!%) ;D ;D

Shawn