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I am a new member to the Corvette Forum and the reason is because of you and your birdcage repair from 2008. I have started an off body repair on my '65 Roadster.
While looking for a rolling frame on eBay, I found exactly what I was looking for and more. It is a completely rebuilt 1965 frame (rest-o-mod) with a 502 Crate engine, drive train, suspension, brakes, EFI, fuel tank, etc.
I was able to remove # 1 & 2 mounts on my '65 but when I got to #3, I encountered the same problem you had with your car. I searched the internet, and your method for repair is the best solution I found so far and decided to go with it.
I did not want to get involved removing fiberglass from the birdcage pillar, and your pictures and descriptions are exactly what I was looking for.
Now all that leads me to my question: Do you have the measurements/dimensions of your metal fabrication for the #3 mount? If you do, it would be greatly appreciated and it would save me time with my friend/metal machinist back and forth with trial and error measurements.
If not, I will attempt to measure the mounts myself but thanks anyway for the excellent solution for my problem.
See attached pictures of my birdcage cancer.
St. Jude Donor '09-'10-'11-'12-'13-'14-'15-'16-'17-'18-‘19-'20-'21-'22-'23-'24
Originally Posted by OldKarz
This thread was started nearly 9 years ago...
Very true, but I dare say we have gained a lot of new members since it started. The problem surely still exists, and the solution shown here would be helpful to a whole new generation of C-2 owners.
While the OP probably no longer has measurements, the overall project is worthy of being revived IMHO.
When looking to buy---does anyone have problems convincing the seller to pull the #3 mount cover for a look............... or kick panel or glove box for that matter?
When looking to buy---does anyone have problems convincing the seller to pull the #3 mount cover for a look............... or kick panel or glove box for that matter?
I have never felt the need to pull panels for inspection, I can inspect using a flashlight to determined the overall condition of the birdcage and frame. The only area that is a crap shoot is the upper windshield frame area but if everything below is good the upper is most likely OK.
If the seller was willing (most are not) to remove anything I would request the kick panels, glove box and #3 mount covers.
I guess the damage was caused by water. Was the small metal plates not seal, thus the water got in. The guy I brought my car from wanted to know why I wanted the plates removed. Your rust issue was why. Fortunately my car did not have any damaged. Not sure I would of purchased it if it had. If there is rust there not sure it could be other places.
Now all that leads me to my question: Do you have the measurements/dimensions of your metal fabrication for the #3 mount? If you do, it would be greatly appreciated and it would save me time with my friend/metal machinist back and forth with trial and error measurements.
If not, I will attempt to measure the mounts myself but thanks anyway for the excellent solution for my problem.
See attached pictures of my birdcage cancer.
I'm not sure why you are seeking dimensions of the mount. The mount is on the frame and you mentioned you have found a new frame to put under the car. I suspect you are seeking information on repairing the rocker panel area of the birdcage - which is clearly rotted through on your car.
I had to make a somewhat similar repair on my car - although it was not nearly that bad. The rocker channel will need to be replaced, repaired, or some sort of sleeve installed - probably in descending order of desirability.
Since you have a roadster, the repair is even more critical as they are structurally less rigid than a coupe. I really doubt you can do an effective repair of that without removing some fiberglass. One reason is that a mechanical repair - such as some sort or bolt in or riveted in sleeve will probably not be sound for a convertible. And the welding necessary to repair the channel or replace the channel would quickly damage and probably set on fire the adjacent fiberglass.
I'm pretty sure they rocker panel sections are available from suppliers. I want to say Caledonia Corvette parts may produce or market them but not sure.
I needed to remove the fiberglass panels behind the #3 mounts in order to rebuild/weld in new fabricated mounts (much heavier gauge metal than the original) on the birdcage. Even though I took my time to avoid damaging, splitting the fiberglass panels, I damaged the exterior fiberglass on one side of the car. Not a problem as I was going to repaint the car anyway. I used cardboard to get a ballpark measurement and measured the exact dimensions on the "B" Pillar. I made a jig made of wood to raise the car one side at a time and clamped the newly fabricated mounts in place, and began the welding process. I set the welder on medium so as not to create too much heat on the other side of the pillar and melt the fiberglass I also kept some wet towels on the fiberglass. As a result, there was no damage to the fiberglass after I was finished welding the new mount. Upon completion of the welding, I whacked the mounts with a 2 lb. hammer to test my work and it passed the test. I am not a professional welder as you can see by the photos but I did my best and welded all the holes and around the mount. I covered all of the surfaces with POR15. The entire #3 mount was rotted away on both sides These are the mounts fabricated for me by a friend. The new mounts in place prior to welding Welding completed on right side. Not a perfect job but did the trick. All exposed metal coated with POR15.
Looks like you had a lot of good metal to work with. I wasn't so lucky,, the entire base was literally gone and just the rubber bushings left on the rusted bolt with no head. You did a really nice job of welding the new metal.
Here are some of the original pictures that were previously attached to the beginning of this thread. Zero issues still with the repair after all these years. Much stronger now than original.
Thanks for the very helpful info... My 67 coupe is lacking the body mount holes, but the B pillars are ok. These pictures gave me ideas to repair my coupe. Very nice work on yours! I have one question, How did you attach to the rocker channel weld, new rocker channel or rocker channel insert?
Thanks for the very helpful info... My 67 coupe is lacking the body mount holes, but the B pillars are ok. These pictures gave me ideas to repair my coupe. Very nice work on yours! I have one question, How did you attach to the rocker channel weld, new rocker channel or rocker channel insert?
01-22-2014, 09:47 AM
