BRAG: My best ones yet., had to share Options

[McMark]

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.