I know I have to replace the left side inner rocker support, most of the bottom of it is rusted out. The car is flexing when lifted. While I was setting it up on the stands to level it I temp put a metal rail across the reinforcement pans and found it does not sit flat on both pans. ( see pic with the arrows) My question is... is 3/16" off the way it is ok, or a bad thing??
How are you leveling the car ? You really need to read the thread I posted on how to level the chassis (I posted the link for you in a previous thread) Your then gonna need to measure the rails as per the frame chart to make sure they are set in the correct position in relation to the unibody / rockers If you look at the dolly I made for my car in my videos & the measuring system I set up that's how you have to do it..any other way is just guessing or a shot in the dark 3/16" is within spec..I would put the reinforcement plate back in if possible WHEN THE UNIBODY & RAILS ARE CORRECTLY LOCATED its one more brace to keep things in place.. The way I would go about your repair is as follows.
1---set car up on dolly or similar at 4 corners of the rocker pinch weld
2--Level front to back & side to side on dolly
3--Set measuring system
4--set rails as per frame dimension chart front & back
5--Install braces as I previously linked to
6--Make all repairs to inner & outer rockers
7--Do not remove any brace work till all structural repairs are complete