Outer rocker panel replacement issue

[70sangersean]

So I'm replacing my outer pass. side rocker and the issue I am having is when I line up the rocker edge with the door edge in the front, so its flush, I end up with a big gap between side of the front pillar and the rocker where it needs to be plug welded. I have my door aligned about as good as you can get with these trucks. If I push the front of the door in anymore it will not be flush with the cowl. I,ve tried two different rocker, one fitting in there better than the other, but both have the same issue. I didn't pay attention to how the original fit, but it had at least a half inch of bondo in it so it probably didnt matter. I know the truck was wrecked in the right front, but retained its original panels (with a fair amount of bondo). The floor, inner rocker, pillar and firewall don't have any visual signs of damage. I've read a lot of threads, and I know I can expect there will be some slicing and tweaking to get them to fit just right. But I haven't read anybody having the issue I have. An 1/8" gap wouldn't concern me but a 3/8" gap doesn't seem right. Any input would be greatly appreciated.
Thanks, Sean

[rechinca]

Sounds like she may have tweaked the cab from the wreck. Have taken measurements to see if the cab is still square and have good body mounts? I read some posts that the body mounts need to be in really good condition before doing this as they disintegrate during the years. I know you have it cut apart already, but I would start checking for square (like you said as good as the manufacturing allowed. You may find some issues along the pillars that are causing the issue too.

[cornerstone]

Pictures would help me understand your problem better. I've only replaced 1 set of rockers but I'd be glad to try to assist.

[70sangersean]

Thanks guys. I will try to get some pics up tonight.

[57taskforce]

I had to slice mine up on both ends of both sides to get them to fit the way I wanted. Pics definitely will help us.

[Southpaw69]

I'm interested in seeing pics too. I'm having a similar issue, it'll get figured out one way or another.

[70sangersean]

Trying to figure out how to upload pics. The site says I'm missing a security token ?

[70sangersean]

What's this security token ? Gotta have so many post before you can post pics ?

[Southpaw69]

Try sizing the pictures down. I think that means they're too big. I could be wrong, worth a try though.

[718jwh]

Don’t know if this will help your situation, but I had a lot of trouble getting aftermarket rockers to fit right so I bought NOS rockers and it make a huge difference. The cost is way more but made installation super easy.

[70sangersean]

http://67-72chevytrucks.com/vboard/a...1&d=1550984250
The factory didn't do the greatest panel line up. As seen in the last pic.

[70sangersean]

Got some pics up. Any thoughts ?
Thanks

[70sangersean]

One last effort. Anybody ?