Out comes the cardboard! (had a hard time finding good cardboard to use... ended up using some old signs we took down at work)

It was ALOT of trial fitting to get the template just right....
https://lh3.googleusercontent.com/-E...Large%2529.JPG

Here you can see how it will take the place of the GM template I used from the rear seat brace.
https://lh5.googleusercontent.com/-t...Large%2529.JPG

Test fit the inner wheelhouse to see how it will work...
https://lh4.googleusercontent.com/-f...Large%2529.JPG

Transfer the template to 1/8th inch steel plate.
https://lh5.googleusercontent.com/-G...Large%2529.JPG

https://lh3.googleusercontent.com/-L...Large%2529.JPG

I have a attachment for my plasma that is suppose to make it easy to cut straight lines... but I found using a piece of wood as a "fence" worked GREAT!
https://lh5.googleusercontent.com/-M...Large%2529.JPG

https://lh6.googleusercontent.com/-B...Large%2529.JPG

Here it is after using a MAP torch and heating the end to create the curve... I also drilled in a few areas so as to be able to plug weld it to the structure underneath.
https://lh4.googleusercontent.com/-T...Large%2529.JPG

Here you can see how much further in the mini-tubs are compared to the "stock" side.

https://lh3.googleusercontent.com/-f...Large%2529.JPG

On to the drivers side...
https://lh3.googleusercontent.com/-D...Large%2529.JPG

https://lh4.googleusercontent.com/-K...Large%2529.JPG

https://lh3.googleusercontent.com/-I...Large%2529.JPG

https://lh3.googleusercontent.com/-N...Large%2529.JPG

Did you see all the spot weld GM used where the inner and outer wheelhouses meet each other. I was original going to try and keep the outer wheelhouse. but after seeing the rough shape they were in and the HELL it was to separate the two... I decided to put new ones in their place. So I drilled all these for NOTHING! :bang:
https://lh5.googleusercontent.com/-3...Large%2529.JPG

Marked off...
https://lh5.googleusercontent.com/-y...Large%2529.JPG

https://lh4.googleusercontent.com/-y...Large%2529.JPG

For Me... one of the tricky parts was making sure this rear curvature was correct to follow the tub. They tell you to come in 2.75" and mark for the cut... but DO NOT do that all the way around.. for the wheelhouse isn't 2.75" larger all the way around... so take your time making sure the curve is as close as you can make it to match the tub.
https://lh4.googleusercontent.com/-H...Large%2529.JPG

Tools I used for the job... (I also used a sawzall)
Side Note: I really didn't use the Plasma that much... it is hard to cut through multiple layers effectively with a Plasma torch... Plus doing it VERY straight. I did use it to make quick rough cuts in some areas... then cleaned it up with a grinder.
https://lh6.googleusercontent.com/-G...Large%2529.JPG

Here is the first "rough cut"... you can see the bottom of the rail is still there.
https://lh5.googleusercontent.com/-p...Large%2529.JPG

That little flange in the front of the opening is left in order to form a lip to make contact with the wheelhouse.

Just clamp onto it and bend it down into place.
https://lh4.googleusercontent.com/-f...Large%2529.JPG

https://lh4.googleusercontent.com/-n...Large%2529.JPG

After cleaning up the initial cut... I am ready to start fitting the brace I will need to make for this side.
https://lh5.googleusercontent.com/-J...Large%2529.JPG

https://lh6.googleusercontent.com/-1...Large%2529.JPG

https://lh6.googleusercontent.com/-V...Large%2529.JPG

Test fit the template on the drivers side...
https://lh3.googleusercontent.com/-Q...Large%2529.JPG

Time to make another brace... transferring the template to 1/8" steel plate.
https://lh5.googleusercontent.com/-N...Large%2529.JPG

I always start the plasma away from my cutline... that way if the plasma sputters or starts funny it doesn't destroy my cutline. I also don't start at the edge, for it seems to produce a bad cutline. (atleast for me)
https://lh3.googleusercontent.com/-A...Large%2529.JPG

https://lh3.googleusercontent.com/-Z...Large%2529.JPG

https://lh4.googleusercontent.com/-X...Large%2529.JPG