* 18 gauge sheet metal cut to preferred dimensions needed. My particular measurements were 10" x 48"
* Low crown body hammer and heel dolly
* Spoon or (flipper) for planishing.
* Sturdy workbench is preferred for this job
* For braking the metal a manual brake was used, but was not absolutely needed. It can be done without it if one is not available. A sturdy bar clamped to a good bench can make a great brake also.
Here you see the inner rocker. It was fairly easy to fabricate by simply putting the metal through the brake and running a couple of beads to strengthen it. The brake can also be completed by clamping the sheet metal to a sturdy bench leaving the portion needed bent hanging over and slowly chasing the steel back and forth with a hammer lightly bending it over a little at a time until it is bent as needed. The beads can be created by clamping the sheel metal to a bench with a piece of 1/4" x 1/2" x 12" piece of steel in between and chasing or "swaging" with a chisel that has been made very dull. If more detail is needed feel free to email me. I will be happy to explain further.
For the outer rocker I started with a piece of steel that I ran through the brake twice to create the bottom portion that you weld to the inner rocker. This could have also been done on a sturdy bench with a hammer as I previously explained. After that portion was completed I ran it through a set of dies made for a reciprocating hammer to create the curve needed. This could have been formed by hand as well. Feel free to email me with questions.
If this article makes it around the internet enought to get enough requests I will create an article explaining the reciprocating hammer and how I built it. ;)
At this point the rocker needed to be sent through the brake 3 more times, but as you know that is impossible with a clamp style manual brake because the bends are 3/4" of an inch apart and the top clamp that holds it down is much larger than that. So I had to make the first bend in the brake and create next two manually by chasing or "swaging" along a bar tacked welded to the bench with a rounded chisel and BFH.
The last bend was made by tipping the edge over the heel dolly shown with a hammer, and then a spoon (flipper) to planish it. This particular dolly has been welded to a post that drops into a receiver hitch that I welded into my bench. That was the smartest thing I ever did.
Here is a pic of the new inner and outer on the car. As you can see I have jacks underneath supporting the corners because I took out a lot of metal and I wanted to insure the door did not sag and everything fit as it should. If you actually use this process and create your own rockers send me a pic. I would love to see them.
If you have any questions regarding any of this process fell free to drop me an email.