I'm installing a third captain's chair on my new (2011) E250. I did the same thing on my 1998 E250, which I'm selling. (Well, I paid someone to do it...). The 98 has a threaded insert from the factory in the C-pillar inside the side barn doors, and the upper seatbelt mount simply threaded into it (see photo). I was hoping my new van had the same setup, but no luck (seems that only the RV-spec package includes it). So I have to get a thread behind the C-pillar sheet metal somehow.
My question: has anyone here done this, and if so, how? There are aftermarket nut plates available, but they are not the thread size that I need (1/2x13). I made up my own with a large fender washer, a nut, and some epoxy, but getting it behind the sheet metal will involve cutting out a big access hole and a lot of frustration, I'm sure. I was also thinking about using a nutsert, but am worried that it will have enough strength in case of an accident.
Any advice is most welcome!
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