I know this isn't new by any means, but I thought I'd post a few pics of my 04 Edge rocker panel repair, using two pieces of 2.5" x 2.5" (id) x 1/8" x 6', they were out of thinner wall tubing (16g) which would have been fine.
The drivers side was even worse, I forgot to take a pic.
Cutting out the rusty bits...
2.5" x 2.5" x 1/8" square tubing cut and notched to fit, I bought two 6' long pieces for $33.95, more then I needed for the job.
The installed (but not finished) rocker panel, a little more welding and finish work is needed.
A family of Fords...
The drivers side was even worse, I forgot to take a pic.

Cutting out the rusty bits...

2.5" x 2.5" x 1/8" square tubing cut and notched to fit, I bought two 6' long pieces for $33.95, more then I needed for the job.

The installed (but not finished) rocker panel, a little more welding and finish work is needed.

A family of Fords...

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