C2 #3 Body Mount Birdcage Corrosion

[Dave K.]

The hole in the birdcage for my 66 Corvette Roadster #3 left side body mount is corroded to about 1 in. diameter compared to what seems to be originally 5/8 in. It is also somewhat raggy around the hole. The #3 body mount is behind the door and is accessed through the inspection hole in the front of the rear fender. I was thinking about making a large square 1/16 to 3/32 in. sheet metal plate, drilled for the bolt, to place over the hole. The rubber mount washer can than sit on the sheet metal plate. Since welding is not practical here the only other solution that comes to mind would be pop rivetting a plate in place.

Any body have experiencd here? Note that the body is off the frame.

Dave Kitch
33108

[Tracy C.]

Re: C2 #3 Body Mount Birdcage Corrosion

Dave,

3/32 sheet metal sounds ok, but 1/8 plate sounds better. Remember, you need to distribute the load induced when you wrench down the bolt to the remaining structure of the birdcage. Fashion a spanner plate that will cover as much area as possible.

I would remove the rusty edge from the existing hole to eliminate the rust and then put a coat of epoxy primer over any bare metal that remains. I think instead of pop riveting the spanner plate, I'd get some metal set epoxy and glue the puppy down. This stuff is now availible in most body shop supply houses. It's fast becoming a prefered alternative to welding repair panels.

This does a couple of things for you. 1) saves you from dinking around with a drill motor and pop rivets in confined space. and 2) eliminates the possibility that water will migrate between the spanner plate and the birdcage and promote a breeding ground for MORE rust.

Heck fire, shoot a little green primer over the top when your done with the bond job, and it will look like it came from the factory this way....

Good Luck
tc

[Gene M.]

Re: C2 #3 Body Mount Birdcage Corrosion

Dave,
Carefull mig or tig welding is possible with care. I would suggest you take some measurements and have a new end piece made at a local tool shop in 14 gage steel and weld it in. Cut cleanly the bad area to correctly place the new piece. It may have to be a U shape taperad off. You will find that the amount of rust out is greater than the local hole for mounting. This affects the door closing if it gets bad enough.

[Joe C.]

Re: C2 #3 Body Mount Birdcage Corrosion

Dave:

Are you doing a full restoration, or just a once-over?

I completed a repair as Gene describes, with some very careful MIG welding and wet rags close at hand. I essentially cut out the last 6 inches of the rocker channels, fabricated new sections, installed, smoothed, and repainted. The repair is very strong, and undetectable. If you have the body off the frame, I think that this is the only way to go.

Entire rocker channels are also available, but the installation would be quite a bit more involved.

Joe

[kelly theaker]

Re: C2 #3 Body Mount Birdcage Corrosion

i am with taking a better look and welding in the rockersill for the mount correctly. this is not really that difficult , but you may need to have a professional do the job if you are not seasoned. do it right if its a nice piece. just my 2 bucks worth. you got an opportunity now , while its off .