How to Install Rocker Panels like a Pro | Squarebody Edition

In this final episode of the welding and rust repair series on my 1987 K5 Chevy Squarebody Blazer, we are officially wrapping up the metalwork, and I couldn't be more excited! After months of cutting, grinding, fabricating, and MIG welding, this classic K5 Blazer is finally rust free and structurally sound. If you've been following along, this is the satisfying conclusion you've been waiting for. If you're new here, welcome to the Squarebody Chevy lifestyle—where we bring these legendary trucks back to life, one weld at a time.

For replacement panels, I use ‪@autometaldirect‬ parts that line up well with the factory door and fender gaps. I take time to fit, clamp, and tweak everything before tacking it in. Door alignment is checked, because it’s easy to weld things out of position and create a nightmare down the line.

Then we get into the custom part of this project—the B-pillar patch panel. This section had rust that went up several inches from the rocker, with holes and thin metal that wasn’t worth trying to save. Since aftermarket B-pillar repair panels don’t exist for this specific area, I fabricate my own using sheet metal. I take time to shape it to match the factory curve and contour of the Blazer rocker panel. This kind of custom fab work is one of my favorite parts of the restoration process—turning steel into structural components that fit like OEM.

Once the patch is ready, I weld it in place using a stitch weld technique to avoid warping. I also reinforce the backside where it meets the cab floor and rocker area, ensuring that the pillar is solid and tied into the rest of the cab structure.

As a Squarebody enthusiast, there’s nothing more satisfying than getting past the rust stage. These trucks are known for their rugged good looks and classic lines—but unfortunately, they’re also known for rotted rockers, floor pans, cab corners, and lower doors. Taking the time to properly repair these areas ensures your K5 Blazer—or any classic Chevy truck—can hit the road safely and confidently for years to come.

This K5 Blazer project has been a labor of love. I’ve documented the journey from tearing out the rust, to fitting patch panels, to welding everything back together. If you’ve missed any episodes, check out the full playlist linked below. Whether you’re working on a Squarebody C10, K10, K20, Suburban, or even a first-gen Blazer, you’ll find tips and techniques here that you can apply to your own build.

I’ll also be posting upcoming episodes focused on bodywork, seam sealing, undercoating, and eventually—paint and reassembly. The vision is to bring this 1987 K5 Blazer back to life as a reliable trail-capable rig that still turns heads at the gas station. This isn’t a show truck—it’s a functional restoration built to be driven and enjoyed.

If you’re into rust repair, fabrication, welding, and classic Chevy trucks, make sure you subscribe and hit the bell so you don’t miss what’s next. Also, drop a comment if you’re working on a Squarebody of your own—I love hearing about your builds and swapping stories with fellow wrenchers.

Thanks again for watching, and for being part of the Squarebody Chevy lifestyle. We’re building more than trucks here—we’re building memories, skills, and a community that keeps these old iron beasts on the road where they belong.