Noticed a while back my running boards sounded like they were coming loose when driving over bumpy roads. Put a socket on them, gave it it a tug and they were all tight. being a bit perplexed, grab the running board and pulled it up/down...damned if it didn't bounce. So I took it off only to discover damage to the rocker sill itself. Pic below.

Only the front most mount looks like this. The second in line has some tears in the metal but the threaded inserts are still in place. Two rear most mounts appear they are fine.

So I need to find some threaded inserts to replace the lost ones, install, flatten the area and weld the tear. Looking for places that sell these inserts and precautions to welding on a late model. Assume disconnecting the battery is adequate, but is it? I'd hate to fry any one of the many computers in this thing.

Local ACE hardware might have some if you can match them.

I'm guessing those are an M8 or so fastener? I've used this style a lot and you can't beat them for holding power.

Threaded Insert

Seeing you are going to weld these work great. weld nuts

the thing that bothers me about welding on the new[er] stuff, is the use of foam all over the place for the NVH protocol.
couple of welds, then 20 minutes later, you see smoke.........

This is a very real possibility. Many "newer" trucks have the rockers filled with a foam that will burn and when it starts burning, will self fuel. The problem is, the dating of the "newer" trucks is different between the manufacturers, so pinpointing at what date how much foam was added is pretty tough to identify.

If there is no foam in the area, and you intend on welding something there, weld on a 1/8" plate with holes drilled with nuts welded to the back to the area where they expected the sheet metal to support a 300lbs + person. The area is already damaged, reinstalling just weld in, or slip in nuts will only be a temporary repair.

If theres foam in there you should see it pretty easily inside the holes.

My Charger is filled with the stuff.

No foam in those areas.

Correct. I shined a light into the holes and I can see it through the length of the sill through the other mounting holes. So no foam in this one.

Any concern with welding on a later model by just disconnecting the battery? Frying a computer isn't high on my "must do" list.

Expansion nuts and weld nut suggestions are appreciated. I will need to determine thread size and pitch to pick some up. Pretty sure they are metric. Some extra metal in these areas isn't a bad idea, however there is no way to put it behind the sill as its all enclosed. Its not a like a frame rail with access to both sides.

You can make nut plates that will get the two top holes on one plate. You fish them through the larger holes in the inner rocker and bolt them to the rocker. Then drill a small hole in the center of the plate and rivet in place. Do the same for the last hole. Once they are in place bolt your running board brackets back in place. No welding needed. Plus they will outlast the truck.

Here is a replacement/repair plate. These are made by AMP research for the power boards but will still work for your problem. Video

Ahh ha, so I'm not the only one who has encountered this problem.

Thanks for finding this and posting!

Less beer and less weight on the board was the reported cause of failure.