Bird Cage Replacement
Burning Brakes
Joined: Aug 2002
Posts: 944
Likes: 1
From: WA
Originally Posted by JonnHeather
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Where did you get all the info on where to break everything apart from? I would like to go that route with mine. dont remember reading a post about it. john
There really is not that much information available in books or online for the bird cage replacement. I used standard I-car repair procedures for the lock pillar and then just redid the t-top bar. I drilled out the plug welds on the t-top bar and plug welded them same as the factory spot welds. On the lock pillar I cut it above the striker (for strength when shutting the door), then made a sleeve out of the old pillar, plug welded it in place and then butt welded the upper and lower halves together using the sleeve as a backer. With the sleeve in there the welded joint will actually be stronger than the original sleeve and since it is the lock pillar it will keep the passenger compartment safer in the event of a side impact. (not that there is much protection without side impact bars in the doors in the early C-3's) All of the fiberglass I broke loose along the factor seems except for the part along the lock pillar, that I just cut and then made a bonding strip out of a donar piece of fiberglass. It took a little time, but overall it was straight forward and with it now being powder coated I know it will never rust again. If anyone needs any more specifics let me know, I would be glad to help...
Where did you get all the info on where to break everything apart from? I would like to go that route with mine. dont remember reading a post about it. john
There really is not that much information available in books or online for the bird cage replacement. I used standard I-car repair procedures for the lock pillar and then just redid the t-top bar. I drilled out the plug welds on the t-top bar and plug welded them same as the factory spot welds. On the lock pillar I cut it above the striker (for strength when shutting the door), then made a sleeve out of the old pillar, plug welded it in place and then butt welded the upper and lower halves together using the sleeve as a backer. With the sleeve in there the welded joint will actually be stronger than the original sleeve and since it is the lock pillar it will keep the passenger compartment safer in the event of a side impact. (not that there is much protection without side impact bars in the doors in the early C-3's) All of the fiberglass I broke loose along the factor seems except for the part along the lock pillar, that I just cut and then made a bonding strip out of a donar piece of fiberglass. It took a little time, but overall it was straight forward and with it now being powder coated I know it will never rust again. If anyone needs any more specifics let me know, I would be glad to help...
Great job!!!!! I am impressed.
Speaking from my own experiences, it is a true vote of confidence you gain when you go this far into a resto and definitely well worth it in the end. She's gonna be a beautiful machine when your done. Keep up the good work. 
Craig
Burning Brakes
Joined: Jun 2003
Posts: 1,212
Likes: 0
From: San Antonio TX
Very nice.
I was wondering how are the corners off the old birdcage?
Are they solid by any chance?
If so, I was wondering if you would be willing to donate (or sell) your old ones? I need both sides.
I wanted to try to repair this one before I give into replacing it.
Here is mine.
I was wondering how are the corners off the old birdcage?
Are they solid by any chance?
If so, I was wondering if you would be willing to donate (or sell) your old ones? I need both sides.
I wanted to try to repair this one before I give into replacing it.
Here is mine.
Last edited by kortensi; Jun 27, 2005 at 04:19 PM.
Le Mans Master
Joined: Oct 2002
Posts: 7,098
Likes: 378
From: Las Vegas - Just stop perpetuating myths please.
Awsome work John!
I salute 1 of the few on this planet that can say they replaced the "Bird Cage". Just the thought makes me want to find another car.Really John as these C3 vettes age and the market for them tightens and prices soar, you will have a great side business for yourself.
Definitly a nich market. 
Man what a way to retire and work on corvettes just when u feel like it. 
Hope 2 c u driving it soon.
cardo0Hey, 1 question. Does the C2 have a "Bird Cage" or does it share the same as the C3?
