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Rust prevention: Drill small hole and spray. (archive)
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Posted by Ivan on December 16, 2001 at 22:43:11:

In Reply to: My plan to fix/strengthen rear sway bar brackets posted by Shawn D. on December 16, 2001 at 21:44:37:

SRC="http://wsphotofews.excite.com/040/Lx/TA/eS/3T39572.jpg">

Here it is from the top. I was rather shocked to see the rust between the two pieces as my car is virtually rust-free. This looks like old rust (pretty dark), so I wonder if it happened during manufacturing, before the phosphate bath & undercoat.

After looking at the frame and the bracket, I plan to weld plates on the front and rear, with the front plate overlapping the frame member. This will put a portion of the interface between the bracket and body in shear instead of simple tension.

These are the rough dimensions of the front plate. When I actually do decent measurements, I'll provide those along with pics of the completed job.

What bothers me most about all this is the potential for rust in the future; I might be able to cover the welds externally, but the coating inside the frame member will certainly be burnt off and I don't know how I'll be able to get to that.




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