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PointedThree :  Vans, Trucks, SUVs and Other Forums : G-Class : Has anyone replaced sills (rocker panels) with 75x50x3 RHS?

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Has anyone replaced sills (rocker panels) with 75x50x3 RHS?
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Posted 4/19/2026 12:55 AM
rhd280
Regular




Date registered: Dec 2014
Location: New Zealand
Vehicle(s): 1982 280GE LWB RHD
Posts: 73
50
Has anyone replaced sills (rocker panels) with 75x50x3 RHS?

Our farm truck a 1982 W460 280GE LWB RHD is showing some corrosion on the sills (rocker panels). Because we are at the end of the earth, shipping premade panels from EU, UK or US is expensive. Making them locally is more expensive.

Has anyone replaced the sills with 75x50x3 galvanised RHS (rectangular hollow section) [3x2x11gauge]?

I read it has been done in South Africa to strengthen the body. It looks fairly straightforward, Cut out the existing sills, clean up, solid weld in place. No worry about jack points as the whole sill becomes a jack point.

In our case, the G is driven about 1,000 km/yr, usually at about 50 km/h, moving stone, poles and gardening kit. It's on an island so no motorways (or stoplights for that matter).

Any thoughts?
#246238
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Posted 4/20/2026 8:55 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3043
2000
RE: Has anyone replaced sills (rocker panels) with 75x50x3 RHS?

Here is a nice solution

http://www.pointedthree.com/disc/forums/showthread.asp?tid=16395&st...

#246239 - in reply to #246238
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