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914World.com _ 914World Garage _ BRAG: My best ones yet.
Posted by: McMark Jan 19 2009, 01:47 PM
I just finished my best front sway bar install yet. Clearance for the inner bracket is always a PITA. Here's how I made these which are pretty much perfect, IMHO.
I made the circle cuts first working from inside the fender.
Then working in the gas tank area:
Drill a hole at the bottom (lowest point) of the center circle. I used an 8mm drill bit, but next time I'd use one that's a bit smaller.
Then I used a Dremel with a cutoff wheel to make a cut RIGHT ON the corner where the inner box metal goes vertical.
Then you can use the Dremel or a hacksaw blade to extend the cut about 1.25" to either side.
Use the Dremel and/or a sharp chisel (I use a wood chisel) to cut down the vertical piece. Or at lease score it so that it will break easily where we want.
Drill out any spot welds that happen to be in the way.
Clean everything up with a 4" file, and use the same file to turn the drill hole into a rectangle that will fit the threaded boss on the new plate.
This car is getting a Tarrett bar. Total time was about 6 hours from start to welded.
Attached image(s)
Posted by: 736conver Jan 19 2009, 01:53 PM
I thought this was going to be for
Brad Roberts Automotive Group.
BRAG
Doh
Posted by: RJMII Jan 19 2009, 02:00 PM
I thought this was going to be for
Brad Roberts Automotive Group.
BRAG
Doh
LOL same here!
Incredibly nice install, though! very much worth bragging about.
Posted by: SirAndy Jan 19 2009, 02:03 PM
I thought this was going to be for
Brad Roberts Automotive Group.
BRAG
Doh
LOL same here!
Three too
I was going to post "So, you working for Brad again?" ...
Anyways, nice install there. I wish mine looked that good. One of these days, i'll have to pay you to redo mine.
Andy
Posted by: Heeltoe914 Jan 19 2009, 02:04 PM
Nice job Now who gets the BILL????
Keep up the good work.
Posted by: KaptKaos Jan 19 2009, 02:13 PM
Nice!
Did you weld on the outside as well?
Posted by: Phoenix 914-6GT Jan 19 2009, 02:18 PM
Well, I guess a few of us thought the same thing.
Very nice work Mark. I need to do the same thing here soon. Maybe mine will look half as nice. Doubtful but here's to hope 
Posted by: sww914 Jan 19 2009, 02:30 PM
Me too. Just seeing BRAG made me feel a little, well, I won't say anymore.
Very nice install, I plan to steal your methods soon.
Posted by: zonedoubt Jan 19 2009, 03:04 PM
Perfect timing for this thread. I'm getting ready to install a front sway bar soon.
Posted by: echocanyons Jan 19 2009, 03:14 PM
Lookin sweet Mark!
Is that a ground tab in the area of the swaybar? Is that for the fuel pump on late cars?
Posted by: McMark Jan 19 2009, 04:21 PM
Yup, that's a ground tab for the fuel pump. I'll be utilizing it when it goes back together.
I knew the BRAG would confuse some of you. I'm so funny in my head. Wait, that didn't come out right... 
Posted by: zonedoubt Jan 19 2009, 05:11 PM
Nice!
Did you weld on the outside as well?
I wouldn't think that welding on the outside is required because the bushing/bracket fits there. Mark, can you confirm?
Posted by: markb Jan 19 2009, 05:12 PM
I thought the same, that somehow BRAG wound up on World.
Nice to see a clean install. I'll be doing that someday soon.
Posted by: McMark Jan 19 2009, 05:49 PM
You don't weld in the wheel well because there is a large aluminum collar that bolts on there. Welding would make it 'unsmooth'. The welding I did is probably way overkill anyway. IMHO, the welds only hold the plate in place so that you can bolt the collar on. The original metal is sandwiched between the steel bracket and the aluminum collar. That compression sandwich is what holds everything together.
Posted by: KaptKaos Jan 19 2009, 06:02 PM
You don't weld in the wheel well because there is a large aluminum collar that bolts on there. Welding would make it 'unsmooth'. The welding I did is probably way overkill anyway. IMHO, the welds only hold the plate in place so that you can bolt the collar on. The original metal is sandwiched between the steel bracket and the aluminum collar. That compression sandwich is what holds everything together.
I have the same bar, that's why I asked. It's too pretty on the outside IMO.
Posted by: Aaron Cox Jan 19 2009, 06:21 PM
BRAG 
but yeah, sick work. I like to throw a few tack welds on em also...
Posted by: ericread Jan 19 2009, 07:03 PM
I'm so funny in my head. Wait, that didn't come out right...
Yeah, I think it came out pretty well...
Posted by: r_towle Jan 19 2009, 08:35 PM
Yup, I thought the same thing...you are funny in your own mind Mark.
We did something similar for Rockets car...we did not have the inners, they were welded in the previous car.
We took some 1/8 plate and cut it to shape, welded on a few nuts and did what you did...a full weld in job.
Not sure if its needed, but mine does come loose and needs to be tightened once a year...maybe I will throw a few welds on mine...hmmm
Rich
Posted by: Krieger914 Jan 19 2009, 08:57 PM
Good work Mark. What about some reinforcing on the fenderwell side like the build in excellence. Any opinions out there?
Posted by: LarryR Jan 19 2009, 09:49 PM
That Looks great!
Posted by: McMark Jan 19 2009, 10:03 PM
http://engmanparts.com/swaybarref.php to reinforce this area. But this is a street car, so stresses will be low and extra bulk is weight not strength in this scenario.
Attached image(s)
Posted by: johnnie5 Jan 19 2009, 10:48 PM
Nice...I am getting ready to install one as well, I can only hope my cuts come out as clean as yours. 
Like the tack in idea as well. 
Posted by: Krieger914 Jan 20 2009, 10:28 AM
63 $ incl shipping...they sure are nice though.
Posted by: jkeyzer Jan 20 2009, 10:42 AM
Nice work, Mark!
Posted by: Rob Ways Jan 20 2009, 03:32 PM
Solid! Good work!
Posted by: tracks914 Jan 21 2009, 08:51 AM
Are the factory ones welded in place?
Posted by: McMark Jan 21 2009, 11:49 AM
Yep, but I don't have a picture of them. They're spot welded, IIRC.
Posted by: sixnotfour Jan 21 2009, 12:03 PM
Mark, is that a new 914 to you ? I see it in your av. so I am wondering if your going green in 09.
Posted by: charliew Jan 21 2009, 12:39 PM
I haven't got a sway bar yet but I would rather drill a few holes in the fenderwell and button or rosette weld the plate in. If welding around the perimeter is to weatherproof the area the bottom didn't get welded so it will still need to be sealed. I guess if the suspension is still in this might be the way to go. Thanks for showing your solution though. It does show the complications of squeezing these parts in.
Posted by: SirAndy Jan 21 2009, 01:11 PM
If welding around the perimeter is to weatherproof the area
No. The Swaybar puts a lot of stress on the thin sheetmetal. Without welding, the metal around the holes for the bolts will eventually rip and break. Welding the backing plate helps transferring the load to a larger area.
Andy
Posted by: zonedoubt Jan 21 2009, 01:19 PM
No. The Swaybar puts a lot of stress on the thin sheetmetal. Without welding, the metal around the holes for the bolts will eventually rip and break. Welding the backing plate helps transferring the load to a larger area.
AndyThat's what I thought.
This is to be my first welding project on my car.
Posted by: McMark Jan 21 2009, 03:43 PM
Nope, it's a customer car. My ugly black 914 is currently sans-engine and partway through some hell hole work. And the Aubergine 914 is still sitting under a cover.
Posted by: McMark Jan 31 2009, 01:42 PM
This car got a hell hole repair as well. This one was also by personal best. My favorite part is that the longitudinal top patch still retains the flange that goes up. Apparently my painting skills aren't up to par though. 
Posted by: ssstikircr Jan 31 2009, 06:06 PM
Good job now I know how to do my sway bar.
Does any one know if a 911 front bar will fit in a 914? 
Posted by: echocanyons Jan 31 2009, 09:32 PM
I am so pleased with the work that you have done on my cars Mark.
This repair is no exception, definitely worth the trip!
Thank you!
Posted by: johnnie5 Jan 31 2009, 11:48 PM
Good job now I know how to do my sway bar.
Does any one know if a 911 front bar will fit in a 914?
Don't 911 front bars run under the car and 914 thru body?
Posted by: McMark Jan 31 2009, 11:52 PM
Some 911s have under body bars, some have through body. But I'm not sure about the interchangeability with 914s.
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