Firebird Torque Box Fabrication
Well, its not really a torque box, but I like to call it that since I don't know what else to call it other than brace or floor reinforcement. Mine (of course) was crapped out and (AGAIN of course) nobody repro's them. I brought them to my fab shop and they wanted $400 to fabricate them!!! I almost crapped my pants. Needless to say it was time to do them myself, but I was a little intimidated by the $400 price tag (must be hard, right?). A Camaros.net poster PitStop Bill gave me some pics of ones he had done (well, satellite pics of them anyway) I was inspired to build my own, so here they are in case someone else needs to make them and can use them as a reference.
One thing that scared me was the curves of the original. in retrospect, I didn't need those strengthening curves, I used a heavier gauge steel than the factory so it probably works out to be the same. I went and got a 2X2 foot section of 16 guage steel from a hardware store (you only really need a 14x14 inch section). The piece mainly consists of three major bends, with the most important being the side that goes up against the frame rail, it has to be at a 70 degree angle to fit right. I just traced everything out on the steel section and cut it out using a air saw. I then bent it up and welded the side that attaches to the inner rocker. After it was all bent up I made a section that the spring cup bolts to and welded that to the unit.

Here is the original piece, notice the side where it attaches to the rocker is all but gone
Here is the first pass, basically it just has 3 bends to it and that little divit on the top (in this pic, it actually mounts upside down) I put the divit in to match the original, and it gives me a good surface to attach it to the inner rocker when its installed
Notice the flap to give that divit strentgh
Here it is with the side mount for the spring cup welded to it. I made that out of a strip of 16 guage as well, but I think PitStop Bill used a rectangular piece of metal tubing

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