Rocker Panel

Complete replacement of the rocker panel (sill) assembly on a 2009 Aston Martin DB9, including removal of door sills, side trim, seat belt anchors, and cutting/welding of the structural panel.

Warnings

Tools required

Parts

• Rocker panel assembly (left or right as needed) × 1 — Use OEM specification
• Door sill trim panel × 1 — Use OEM specification
• Rocker panel molding/side skirt (if damaged) × 1 — Use OEM specification
• Seam sealer cartridge × 1 — 3M 08308 or equivalent
• Anti-corrosion primer × 1 — Use manufacturer-approved product
• Trim panel clips (assorted) × 10 — Replace damaged clips as needed
• Weld-through primer × 1 — Use manufacturer-approved product

Preparation

1. Park vehicle on level surface in well-ventilated workspace with concrete floor.
2. Disconnect negative battery cable and isolate to prevent electrical shorts during welding.
3. Raise vehicle on appropriate lift or jack stands at manufacturer-specified lift points, ensuring stability for extended work period.
4. Remove wheel on affected side to improve access to lower rocker panel area.
5. Identify and photograph all wiring harnesses, brake lines, and fuel lines routed near rocker panel for reference during reassembly.
6. Cover adjacent painted surfaces and glass with welding blankets or heat-resistant material.
7. Verify replacement rocker panel matches original in mounting points and dimensions before beginning removal.

Procedure

1. 1

   Remove door sill trim panel
   Open door on affected side. Locate and remove Torx fasteners securing door sill trim panel (scuff plate). These are typically T25 or T30 fasteners along the length of the sill. Carefully lift sill trim panel upward from rear to front, releasing any remaining clips. Disconnect any puddle light electrical connectors if equipped. Set trim panel aside.
2. 2

   Remove lower door trim and seals
   Peel back door weatherstrip seal where it contacts the rocker panel area. Remove lower door trim panel if it overlaps the rocker panel junction. This typically involves releasing clips at the bottom edge of the door card. Work carefully to avoid breaking trim clips. On DB9, the door seal may be bonded at the A-pillar and B-pillar areas; gently separate without tearing.
3. 3

   Remove side skirt/rocker panel molding
   Locate fasteners securing the external side skirt or rocker panel molding beneath the door openings. DB9 uses a combination of push clips and threaded fasteners; the exact number and locations of sill/skirt fasteners must be verified against the Aston Martin DB9 body repair documentation before removal. Carefully pull molding away from body, releasing any remaining retention clips. Inspect for hidden fasteners at front wheel arch and rear quarter panel junctions. Note: Remove the side skirt fasteners along the length of the skirt (verify exact count and locations against the Aston Martin workshop manual).
4. 4

   Detach seat belt lower anchor point
   Locate seat belt lower anchor bolt at B-pillar base. This is a high-strength hex-head anchor bolt; verify the exact head type and size against the Aston Martin workshop manual before selecting tooling. Remove bolt completely and secure seat belt retractor assembly out of the way. This anchor point is structural and will be re-established during panel installation. Note: Locate the seat belt lower anchor bolt at the B-pillar base where it mounts through the sill structure. This is a high-strength fastener; confirm the exact head type and size against the Aston Martin workshop manual before removal. Note: This is typically a high-strength torx/E-torx bolt; the exact drive type and size must be verified against the Aston Martin DB9 workshop manual.
5. 5

   Remove carpet and interior access
   Pull back interior carpet along the rocker panel area to expose the inner sill structure. DB9 carpet is typically secured with Velcro strips or clips along the sill edge. Remove lower B-pillar trim panel by releasing Torx fasteners and clips. This exposes the interior side of the rocker panel and allows inspection of inner structure condition. Remove any sound deadening material attached to inner sill area.
6. 6

   Protect and isolate nearby components
   Identify all wiring harnesses routed along or near the rocker panel, particularly at A-pillar and B-pillar areas. Disconnect harness clips and secure wires away from cutting zone using tape or tie-wraps. Cover brake lines and fuel lines (if present in rocker channel) with heat-resistant wrap. Remove any plastic clips, fasteners, or grommets attached to the rocker panel that will be destroyed during cutting.
7. 7

   Mark cutting lines and drill spot welds
   The DB9 bonded aluminum sill is joined by structural adhesive and self-piercing rivets, not spot welds. Replacement requires removal of rivets by drilling and softening/separation of adhesive bonds per Aston Martin structural repair documentation. Spot-weld drilling does not apply to this platform. Obtain factory joint locations and rivet counts from the Aston Martin workshop manual. The DB9 sill is bonded and self-piercing-riveted aluminum; spot-weld counts do not apply. Note: The DB9 sill structure is bonded and self-piercing-riveted aluminum, not spot-welded steel. Rivets must be drilled out and bonded joints heated/separated per Aston Martin's aluminum structural repair procedure. Spot-weld counts do not apply; refer to the factory manual for rivet locations and quantities. Note: Using the replacement panel as a template, mark the separation lines on the existing aluminum sill where it is bonded and riveted to the floor, A-pillar base, and B-pillar junction. Identify self-piercing rivets (SPR) and bonded seams. Drill out rivets and break the structural adhesive bond per Aston Martin structural repair documentation. The exact rivet count and bond-line locations must be verified against the official VH structural repair manual before beginning.
8. 8

   Cut and remove damaged rocker panel
   Drill out the self-piercing rivets and separate the bonded adhesive joints using Aston Martin-approved tooling and controlled heat. Do not use a plasma cutter on the aluminum structure. Clean residual adhesive from mating surfaces mechanically and achieve smooth mating surfaces on floor pan and pillar flanges. Inspect the exposed aluminum inner rocker structure for galvanic/pitting corrosion or collision damage requiring additional repair. Note: Using appropriate aluminum-safe cutting tools, carefully separate the sill section after all rivets are drilled and adhesive bonds are released. Work slowly to avoid damaging the inner aluminum spaceframe structure. Clean residual adhesive and prepare mating surfaces per Aston Martin aluminum repair spec. Inspect the exposed inner spaceframe structure for corrosion or collision damage requiring additional repair.
9. 9

   Prepare mating surfaces and fit new panel
   Clean all mating surfaces with aluminum-dedicated abrasives (do not use steel wire brushes, which cause galvanic contamination). Address any galvanic/pitting corrosion per the Aston Martin aluminum structural repair manual. Prepare mating surfaces and apply the Aston Martin-approved adhesion primer/bonding system to all surfaces that will be joined, per the structural repair manual. Position new rocker panel into place and secure with self-locking panel clamps at multiple points. Verify alignment with door openings, wheel arch, and adjacent body panels using panel alignment gauge. Door should open and close freely with new panel clamped in position. Check gaps and flush alignment at all panel junctions before bonding and riveting. Note: Clean all mating surfaces and abrade to prepare for bonding per Aston Martin aluminum repair spec, avoiding contamination. Treat any aluminum corrosion per manufacturer guidance. Apply the manufacturer-approved structural adhesive/bonding system to all surfaces that will be joined.
10. 10

    Weld rocker panel at primary attachment points
    Apply Aston Martin-approved structural adhesive to the prepared aluminum mating flanges and set self-piercing rivets at the factory-specified locations and pitch using the correct riveting tool. Do not MIG weld. Follow adhesive open-time and cure requirements; clamp panel until adhesive sets at the front and rear termination points. Note: Join the replacement aluminum sill using the factory-specified structural adhesive and self-piercing rivets (or Aston Martin-approved flow-drill screws) at the locations and intervals given in the workshop manual. Do not MIG weld; steel welding methods are incompatible with the bonded aluminum VH structure and will compromise crash performance. Note: Beginning at the B-pillar junction, install new self-piercing rivets (or specified structural rivets) at the factory rivet locations and intervals while the structural adhesive is wet, per Aston Martin VH repair documentation. Follow the manufacturer-specified rivet type, spacing, and adhesive cure requirements. Aluminum MIG/TIG welding, if specified, must use aluminum-rated equipment and settings for the actual panel thickness.
11. 11

    Complete seam welding and finishing
    Verify all rivets are fully set and structural adhesive has cured to spec. Confirm joint integrity at A-pillar base, B-pillar base, and jacking point reinforcement per the Aston Martin structural repair manual. No seam welding is performed on the aluminum structure. Verify joint integrity by inspecting rivet seating and adhesive coverage at multiple points per the Aston Martin workshop manual. Do not disturb curing adhesive. Inspect for any gaps or improperly set rivets requiring correction. Note: After adhesive application and riveting are complete, allow the structural adhesive to cure fully per Aston Martin specification before loading the joint. Verify rivet seating and joint integrity per the workshop manual. Do not grind structural rivets or welds; follow factory finishing steps for the bonded aluminum sill. Note: After all rivets are set and structural adhesive is applied and cured per spec, verify the joint is structurally sound. Clean up any excess adhesive. Inspect all rivet locations and bond lines for proper seating and full adhesive coverage, adding fasteners only where the official repair documentation specifies.
12. 12

    Apply corrosion protection and seam sealer
    Apply Aston Martin-approved corrosion protection to all bonded/riveted areas, both interior and exterior surfaces. Pay particular attention to flanges, rivet joints, and any areas where bare aluminum was exposed, to prevent galvanic corrosion. Apply seam sealer to all panel junctions, creating a continuous bead that matches factory seam sealer locations. Tool seam sealer smooth to replicate factory appearance. Allow sealer to cure per manufacturer specifications before applying finish coatings. Note: Apply manufacturer-approved aluminum-compatible corrosion protection to all repaired/bonded areas, both interior and exterior surfaces, paying particular attention to flanges, rivet areas, and any bare aluminum exposed during the repair. Apply manufacturer-approved seam sealer to all panel junctions, matching factory locations.
13. 13

    Reinstall seat belt anchor and verify mounting
    Reinstall seat belt lower anchor bolt through rocker panel structure at original mounting point. If the new panel required drilling for the anchor bolt, ensure the proper reinforcement backing is installed per the Aston Martin aluminum structural repair manual (bonded/riveted, not welded) behind the mounting point. Torque the seat belt anchor bolt to the exact manufacturer specification from the Aston Martin workshop manual (do not rely on a generic estimate such as 35-45 Nm for this critical safety fastener). This is a critical safety component and must be properly torqued and structurally sound. Note: Torque seat belt anchor bolt to the exact manufacturer specification from the Aston Martin workshop manual (do not rely on a generic estimate for this critical safety fastener). Note: Torque seat belt anchor bolt to the exact manufacturer specification taken directly from the Aston Martin DB9 workshop manual. Do not use an estimated value for this critical safety fastener.

Reassembly

1. Reinstall interior carpet and sound deadening material along rocker panel, ensuring proper fit without wrinkles or gaps.
2. Reinstall lower B-pillar trim panel and door sill trim panel, replacing any damaged clips.
3. Reinstall door weatherstrip seals, ensuring proper sealing at A-pillar and B-pillar junctions.
4. Reinstall external side skirt/rocker panel molding, verifying alignment with adjacent body panels.
5. Reinstall wheel and torque lug nuts to specification.
6. Reconnect battery negative cable.
7. Panel will require body filler application, sanding, primer, and paint to match vehicle finish.

Verification

• Open and close door multiple times, verifying smooth operation without binding or interference with new rocker panel.
• Inspect all weld points for complete penetration and no visible gaps or cracks.
• Verify panel alignment by checking gaps at door openings, wheel arch, and adjacent panels - should be consistent with opposite side.
• Confirm seat belt anchor bolt is torqued to specification and seat belt retracts and extends smoothly.
• Check that all wiring harnesses are properly routed and secured away from sharp edges.
• Verify no fuel or brake line damage occurred during welding operations.
• Test vehicle on lift or jack stands to ensure structural rigidity with no flexing at rocker panel area when doors are opened.

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