Below is the photo of what I need to replace, (75’ coupe) I was going to try to remove the existing metal insert, and replace it will a fabricated one by me. Anyone have the dimensions for me to fabricate one out of let's say 14 gauge? Any tips on removal as both sides will need to be replaced? I was thinking of cutting out a 3.5" x 4" section from below, then using an impact chisel and removing the insert from below. Installing the replacement from above and tig welding a 3.5"x 4" plate from below. All would be from 14 gauge, so it would be easy to form a new insert.

I was also going to cut out a section below and tig weld a new plate.

 

I did not take measurements of the #2 insert before I put it in. Should have.

If you look at my pictures you will see what I did. I have quite a few in my album. Others have done it as well. I used a plasma cutter to cut out the opening in the #2 ... its a pain cause you neck and welding helmet dont fit good in that confined area. I then used a die grinder and or sawsall to finish the opening. My #3's came out with channel locks they were so bad and I had to rebuild it and used the #3 insert as well after removing the entire fiberglass access panel so I could get in there and will just bond in a replacement one. Dont get me started on replacing the #4. I hated this whole job the real key to working on the rocker channels is having a way to get at them and most home made dollys have a board running down the entire length. I had to buy a body dolly where the area was open and I could support the body by the floor pan for complete access to the rockers.

The insert material is about 1/8" thick. They arent cheap at $100 each but they are pretty well made and well thought out. It depends how much time you have to make one yourself and what access to tools etc to bend, weld one yourself. I put in all three pieces on mine cutting out the portions that were bad and leaving in what was still good.

I have seen guys just make up a U shaped replacement and weld that in but you would have to measure that up your self and make it work.

 

Thanks for the reply mysixtynine;

If I may ask a few questions;

I have a plasma cutter although I'm not very good with it, but I'm curious as to why you didn't cut out the opening from the bottom with a cut off wheel?

When you said the insert material was 1/8" and around $100.00 did you purchase or make them and was that each?

1/8" metal is around 8-9 gauge which is thicker then the frame itself, I didn't think oem was that thick?

Since I have the body off repairing #4 and #1 was actually easy on the frame, only #2 and #4 need replacement on the body.

Does anyone have the dimensions of the #2 body mount inside the kickpanel?

 

I cut the #2 out from inside the car and then cleaned it up from underneath with a die grinder because I simply HATE cutting metal or burning metal above me when I am on my back. I hate the metal bits and possibility of getting that crap in my eyes. Also from inside I knew exactly where to cut, from underneath you could mess up and there is too much fiberglass that can catch on fire.

These inserts are really well made and worth money if you have to go this route. I had to use all 3 parts to fix my rockers. They are really solid now. I can send you more pic via email if you want.

The #2 inserts are $100 per (it also recreates the #1 mount as well). Front http://www.zip-corvette.com/ProductD...ptct=&CTitle=&

Rear http://www.zip-corvette.com/ProductD...ptct=&CTitle=&

Center http://www.zip-corvette.com/ProductD...ptct=&CTitle=&

 

The body mount locations in both A and B pillars for both sides were rough, so I cut out all 4 body mount areas and installed new 3-piece rocker channel inserts from Corvette Central. I also repaired all 4 body mount brackets on my frame.

http://www.parts123.com/parts123/yb....~Z5Z5Z50000050

http://www.parts123.com/parts123/yb....~Z5Z5Z50000050