Very interesting observation! In reviewing the first pics, I see the hole that you are referring to. I did not take anything out of that hole, so I'll have to rely on others who have more experience to tell me if that is supposed to attach to something else. I agree with your point, though. That's why I stated that I couldn't figure out the real purpose of that part. I'll get back out there tomorrow and see if I can figure something out.
In checking the FAM, the correct name is "hinge pillar reinforcement." It is identified on section 1 sheet 35.00. At least that's the first time that I could find it. Interestingly enough, it does show the hole in the rear of the piece. It does not, however, show any connection related to that hole. At least in that drawing. I did not notice any other references to or drawings of that piece in the FAM.
It sounds as though you would recommend making the piece out of a thicker piece of metal. I can certainly try to do that. Thicker would seem to offer more structural strength and/or rigidity to the pillar, even if no other connection is made through that hole. It seems to me, that as a reinforcement piece, having it spot welded to the pillar above and below the weld nuts and spot welded to the sides of the pillar, as GM did it originally, does offer more structural rigidity. Even if nothing is bolted to it. Would it be enough to hold that door? I don't know.
Thanks for the feedback! Keep it coming! I'm definitely going out to look for that connection, or the remnants of it.... I'll also take a swing at making a new version with thicker metal.
