Rocker panel badly rusted

[silencer]

Hi!
My first post.
I purchased a recently inspected out of province vehicle and it turns out it should not have passed...
There is such bad rust along the rocker panel (the strip below the doors) that underneath (the only way you can see it is on a hoist) there is a one inch hole that runs about 2 feet long on each side. From the outside the 99 Grand Vitara looks fine.
It failed inspection here in any case.
To order new pieces and have them welded in is $5000
Does anyone have any suggestions?
Is there a wreck that someone knows of where I could buy those 2 pieces and have them shipped to me?
Would there be some interchangeability with another vehicle?
Is there an aftermarket roll bar or running board that could be installed to restore the structural integrity?
Is there any sort of body mod that could be done?
Ideas?

Thanks for your assistance.

[Steviejay]

Its funny that you mention this, I just bought a 1999 Grand vitara GV2000, and I noticed that when I got it home it looked like it had some metal plates welded in this exact place and painted black,
Its the same on both sides.

Is this a common problem on these then?
I'm in the UK btw.

[murcod]

I'm sure I've seen a "how to" somewhere on a US website for removing these panels and replacing them. Sorry but I can't remember where it was, I've got a feeling they made replacement sliders or something to replace them with?

[lord_galathon]

Rocker panels are the first part that will rust on Sidekicks and Vitaras unless properly rustproofed and oiled at least yearly.

I've had one replaced on a Sidekick for 150$, they welded it on for me. All I did afterwards was paint it. I didn't care that it had some weld lines and I didn't bother finishing it properly with putty etc.

My own 1999 Vitara has rust holes in the rocker panels. Trouble is that there are wiring harnesses in there so you have to be careful.

[silencer]

Thanks all. After a week of phoning around, I found a wrecked 2003. I HOPE THEY FIT!~
For $200 a side, they will cut out the rockers and I will have a body shop install them.... trouble is the qoute is $1500 to cut out the old ones and weld in the new.

Turns out I had to buy a suspension cross member too, it had been 'farmer' welded and had a hole in the passenger side.....
I should post some pics.

[murcod]

Far out that's bad.

I hope you can get it fixed OK.

[Max]

Wow. That's a lot of rot!

Speaking as a metal fabricator and automotive restorer / hobbyist...there is a significant work load ahead in an area that is mostly structural. The price you state isn't out of line. In fact it could escalate. If you go "CHEAP", that's just what you are going to get and you won't be pleased with the results.

Replacement metal sections from a 03' to fit a 99'? That's a pretty big leap in model years. I'd confirm / measure / compare the donor portions prior to committing to purchase if I were you.

I'm additionally concerned w/what you CAN'T see until one is cutting and hunting for decent metal for which to join to.

Part of me says unless the REST of the vehicle is in outstanding condition / low mileage, I'd unload this one. This may not be what you want to hear though.

[silencer]

Thank you for the advice, Max. It sounds reasonable, but since this was out of province I can't register it until repaired - and I was offered $500 for scrap.

Apparently we ALL have the crossmember issue. Everyone should check theirs now.
http://www.suzuki-forums.com/1g-1999...er-recall.html

There is a general recall for the part via CHEV TRACKER.....
so I have to cancel the used part until I find out 1) if suzuki will replace this 2) if not, is the used part just as bad?

EDIT: The dealer says it is a recall issue and booked it for Tuesday for inspection.

[Max]

The cross member recall is one thing. The extensively deteriorated ROCKER issue you have is another. No?

You may get SOME monetary relief if you can obtain the apparent recall support in conjunction.

[silencer]

You mean ask the dealer to see if the rocker panel is covered as well?

I am hoping that if I strip out the carpet, mouldings, and put it all back on my self I can shave a few hrs off.