I have one body mount hole that has enlarged due to rust... instead of a nice round hole - it is oval and nasty.

Is there a way to cut a rectangular area out of the rusted area, and weld in a new plate with a new hole?

Has anyone else done this?

Joe

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Joe Beyer
1969 Malibu Convertible (kinda)
http://www.chevelles.com/showroom/convtrailer.jpg
Home Page (http://JRBeyer.tripod.com/index.html)

Hey Joe (Good Jimi H tune)
Although I haven't yet, I plan on the same repair for a couple of my body mounts. My brother works in a fab shop so I'll have him get the proper gage and punch whatever size hole I need.

I have already done a similar repair for the sway bar bracket area on the right front. That area was badly rusted so I cut back to good metal and welded in a patch. Then just drilled/tapped the holes for the bracket.
B~


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Brian
66 SS396 frame off WIP
"If things ain't going right, go back to sleep. Dreams will get ya there."

oh yes, i have! see some pics http://members.aol.com/smartasreality/page3.html i have done exactly what you are describing but dont have those pics but these will give you an idea.

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Only in America do they have drive-up ATM machines with Braille lettering and people leave cars worth thousands of dollars in the driveway and put our useless junk in the garage. www.EINSTYN.com (http://www.EINSTYN.com) TC#1460, VCEA#2
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1970 Chevelle 454 Wagons

I will take a large washer with the inside hole being the same as what it should be,use the outside as a pattern to cut out the bad area,then fit it in , weld an grind smooth you will never tell its been replaced.These you can get at your local hardware store.

Brian - I'm a woodworker in my spare time - but I don't think I've ever seen a circle cutter for metal - is this a fab shop only type thing????


FO_FDYFO Can't see your pics http://www.chevelles.com/forum/frown.gif What guage did you use - did you cut the circle with a plasma cutter?

Bill - I don't think I've seen a washer with the i.d. of a body bushing - maybe I'm wrong...

Joe

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Joe Beyer
1969 Malibu Convertible (kinda)
http://www.chevelles.com/showroom/convtrailer.jpg
Home Page (http://JRBeyer.tripod.com/index.html)

There are hole saws for metal, too and they come in many sizes.

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Leo Paugh
Maryland Chevelle Club #017
A.C.E.S.#3731
progress has little to do with speed, but lots to do with direction.
Maryland Chevelle Club (http://www.chevelles.net/mcc/mcc.htm)

Joe
Yes there are hole cutters for metal but....

I'm lucky enough that where my brother works I can get just about any size I need punched. He got me the patch for my sway bar area.

To be honest I rebuilt my chassis up to the body mount repair and stopped. I then switched and started working on the body (it's outside under a shelter ... I needed keep it from turning into fertilizer).

If you're at stage and need them now I can get him to punch the patches I need and a couple extra to send to ya. Just give me an email.
B~

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Brian
66 SS396 frame off WIP
"If things ain't going right, go back to sleep. Dreams will get ya there."

OPGI sells a "body mount repair kit", it's just a set of washers that are all the correct size.
I actually got the washers for my repair from Mcmaster-Carr. I had to order them because the washers at the local hardware store didn't have the right inside diameters.

Brian
( A different Brian with a 66 SS frame off WIP)

I did it like this,first make a template of the hole off another mount.Then cut out a square a little bigger than the rusted area.Take the square you just cut out and trace it on a peice of steel the same guage(3/8? i forget now)Cut the new peice out,trim it so it will drop right in the square you cut in the frame.Butt weld in the new peice, grind it flat.Lay the template on,trace out your bushing hole,then cut it out with the right size hole saw,i think it's 1 1/2".There may be easier ways but this way is strong and undetectable when your done.

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http://photos.yahoo.com/ochrisl

i used a plazma cutter and a 1/4" plywood circle guide. i'm working on getting the pics to work. sorry about that. also my 70 has 1.5" holes you can get them from McMaster carr part number 97063A520 . phone number 732-329-3200. also i have seen them in one of the common chevelle parts supliers catalog.

this should work. http://www.chevelles.com/forum/smile.gif http://members.aol.com/smartasreality/images/frame03-17-02a.jpg http://www.chevelles.com/forum/smile.gif
http://members.aol.com/smartasreality/images/frame03-17-02b.jpg
was: http://members.aol.com/smartasreality/images/frame-02-25-02o.jpg

[This message has been edited by FO_FDYFO (edited 04-15-2002).]

[This message has been edited by FO_FDYFO (edited 04-15-2002).]