Since the front sway bar mounting area is prone to fatigue when using a bigger sway bar, which I am (suspension techniques), I reinforced the area with a 3mm thick piece of fresh metal!:)
What we’re working with before:CSD disk removed the old paint and rust quickly:Here are the new 3mm thick reinforcement plates:Coated them, as well as the frame rail, in a coat of zinc spray where both metals would overlap each other, to prevent any rust if water would find its way between the two!Bolted the plates onto the frame rails:Removed the zinc spray coat around the plate to prevent welding spatter:And welded them right in! Welding over head is a bitch! One side turned out quite pretty in cosmetical terms though, as I was able to have a better posture for it!:)That’s the prettiest weld I was able to achieve: BTW: I stitch welded the plates first, to reduce heat, to then fully seam weld the gaps, so less water could find its way between the two metals!The other side turned out the ugliest, but still everything is plenty strong!:)I still ground down the prone welds flat to the plate, so nothing would interfere with mounting the sway bar later on!And a coat of zinc spray to protect the metal for now!
See you in the next post, hopefully in the near future!;)