C2 67 core support repair

[Jim K.]

Anyone have any experience replacong the lower (usually rotted) member of the core support? Mine is rotted by the radiator carriers but is rock solid everywhere else. Many vendors sell just the lower part, and it looks like it will go in fairly strait forward (plus $96 is better than 300+).

[Lynn H.]

Re: C2 67 core support repair

I have done this repair, and it works out fine. You can drill out the spot welds on the old piece to remove it (they make an inexpensive tool for drilling these out), and plug weld the new one in through the spot weld holes. If the rest of the core support is solid, this is a very viable repair.
Lynn

[Jim K.]

Re: C2 67 core support repair

Thanks Lynn! Any pictures or info on ALL of the spot welds? Seems like a dozen on each side of the back side, any on the front?
Jim

[Lynn H.]

Re: C2 67 core support repair

Jim,
What I tend to see in most of the spot welding situations, is even though there are drawings that state how many and how far apart, there is a serious lack of any consistency. In the AIM book you can see where they call out spot weld specifications for the birdcages which were assembled in St. Louis, but I believe the core supports were supplied to the plant as an assembly (John H. could confirm that if he sees this thread). You pretty much have to approach each one of these situations individually and see how many welds there are. Lots of times welds are very close to each other, and on the edges, and can be more difficult to drill out, but if you take your time it goes pretty well. There are usually a couple of tack welds and shorts beads also on the midyears core supports. These are fairly straight forward to remove, I use a cut off wheel on the die grinder and a pencil grinder with a small carbide bit to separate them. Here are a couple photos from a nice 65 AC support that show some of the tack and spot welds. If you want some more or better pictures send me your email by PM and I will get you some possibly better photos.
Lynn

[John H.]

Re: C2 67 core support repair

I believe the core supports were supplied to the plant as an assembly (John H. could confirm that if he sees this thread).

Lynn -

That's correct - the passenger car radiator supports were welded up in the assembly plants, but the Corvette supports were received as a complete welded assembly from the supplier.

[Jim K.]

Re: C2 67 core support repair

Thanks Lynn and John! I wire brushed my (I think) original and see what looks like spot welds but really just look luke hammer marks, bo welded seams and the cross brace rod is welded there. I'll begin carefully pulling apart (after marking some reference points for reassembly) and order the replacement part... Thanks again!!!

[Thomas N.]

Re: C2 67 core support repair

Jim:
There are resistance spot welders (look like a pair of tongs) available to come close to the original spot welds. Plug welding and grinding, which is a viable repair, doesn't replicate the spot weld visually. When you get to the point to spot weld this, let me know and I can get it done for you or can maybe get the tool to you. That is if you want to pursue that approach. Heck, if you are going to the 5/11 meet, I might even be able to bring the tool down.

[Lynn H.]

Re: C2 67 core support repair

Jim:
There are resistance spot welders (look like a pair of tongs) available to come close to the original spot welds. Plug welding and grinding, which is a viable repair, doesn't replicate the spot weld visually. When you get to the point to spot weld this, let me know and I can get it done for you or can maybe get the tool to you. That is if you want to pursue that approach. Heck, if you are going to the 5/11 meet, I might even be able to bring the tool down.

I also have a spot welder, but disassembly becomes more of an issue as drilling out the old spot welds removes the material unless you weld the holes back up first. More time consuming but can be done. Getting the spot welds separated can be tough sometimes without major distortion of the surrounding material.
Lynn

[John L.]

Re: C2 67 core support repair

Jim/Gail

Very doable repair. spot or plug welds are pretty much hidden by frame.

[Paul J.]

Re: C2 67 core support repair

Jim:
Plug welding and grinding, which is a viable repair, doesn't replicate the spot weld visually.

Plug welding is the way to do the repair. Do the plug welds, grind it flat, then take a 3/16" punch and strike it hard between the plug welds. Looks just like spot welds, and very difficult to tell after it's painted.

Paul