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> Torn Rear Suspension Ear, drivers side inner console damage pictures
brant
post Jul 25 2006, 02:17 PM
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Thanks Mike,

regarding the strap.
its really a heavy guage piece.
I suppose it could flex, but its pretty thick.

part of the reason for the strap was to move the bar outboard.
it provides more space for the -6
and also structurally straightens out the angle to a stronger one.

On my -4 (no current picture of its brace) the similar bolt in brace goes from the inboard bolt to the firewall with out this "strap piece"

The strap piece is version #2 and was an update by my race shop. He installed the version #1 on my -4 cylinder car about 10 years back.

He felt that this was a better design, I think mostly because the brace bar is going nearly straight forward.

brant
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lapuwali
post Jul 25 2006, 02:23 PM
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Believe me, that strap WILL flex. If the huge boxed-section trailing arm flexes under those loads, a flat bar is going to flex, too. The arm will limit the flex to some degree, but having the arm directly attached to the ear would be a far stronger option (lighter, too). As always, there are practical considerations, and moving the parts outboard to make room for the engine is one of them.

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Brett W
post Jul 25 2006, 05:38 PM
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QUOTE
My car just had a removable brace installed similar to Brant's. I don't have a pic as it's still in the shop. I also have a bar going from the rear of the suspension ear to the tranny mount structural member, plus two more at the top of the shock tower rear to the tranny mount brace and forward to the roll cage. All the work was done by TRE. Here are a few pics that show some of the bracing but not the removable one like Brants


All the bracing in the trunk does nothing for chassis rigidity. The chassis doesn't flex that way. You should run bracing in line from the firewall to the strut and to the inner suspension ear. Also a brace between the frame rails at the firewall, struts and below the engine will make a difference.
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kdfoust
post Jul 25 2006, 07:17 PM
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QUOTE(drew365 @ Jul 25 2006, 08:02 AM) *

My car just had a removable brace installed similar to Brant's. I don't have a pic as it's still in the shop. I also have a bar going from the rear of the suspension ear to the tranny mount structural member, plus two more at the top of the shock tower rear to the tranny mount brace and forward to the roll cage. All the work was done by TRE. Here are a few pics that show some of the bracing but not the removable one like Brants


Hey Drew365:

What the heck is the thing that I circled in blue? What's it attached too,...,...?

Regards,
Kevin


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ChrisFoley
post Jul 26 2006, 06:58 AM
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I took a look across the engine compartment and here's what I saw. (IMG:style_emoticons/default/sad.gif)


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ChrisFoley
post Jul 26 2006, 06:59 AM
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bottom side detail


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ChrisFoley
post Jul 26 2006, 07:01 AM
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Repairs to the driver's side are underway.
I cut off a portion of the inner ear and found several more non-fused spot welds.



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ChrisFoley
post Jul 26 2006, 07:07 AM
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This piece had some perf but it is a lot easier to repair than replace.
The inner reinforcing layer was still good but the outer layer was badly rusted along the crack and around the bottom edge of the trailing arm mounting surface.
All the perf is filled with weld and the cracked area cut away.
This can be rewelded onto the car after just a little clean up.


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ChrisFoley
post Jul 26 2006, 07:10 AM
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Back on the car...
I pushed the lower portion back into place and welded it up along the forward pinch weld flange.
I also cut away the rusted area near the crack.
The next step is to wire brush the inside and coat with POR 15 before welding the small piece back on.


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ChrisFoley
post Jul 26 2006, 07:14 AM
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After the repair is complete I will be welding on these reinfofcing pieces.
I also plan to make similar pieces available for others to reinforce this often overstressed part of the rear suspension.


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ynotdd
post Jul 27 2006, 07:00 AM
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Chris looks like you are doing a great job!!! Its scary to think I was over 100mph in that car days earlier!!!! I will try to call later today didn't want to interupt you. (IMG:style_emoticons/default/flag.gif)
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thesey914
post Jul 27 2006, 11:42 AM
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When the inside is coated with por15 can it be welded through or do you leave the area to be welded un-painted?
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ChrisFoley
post Jul 27 2006, 07:33 PM
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QUOTE(thesey914 @ Jul 27 2006, 01:42 PM) *

When the inside is coated with por15 can it be welded through or do you leave the area to be welded un-painted?

If I will be doing any welding nearby I don't put POR15 any closer than about 1/2" from the weld zone. I am using 3M Weld thru coating spray on all the weld zones and self etching primer in a can on all the exposed bare metal surfaces after cleanup.
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ynotdd
post Jul 29 2006, 02:53 PM
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any updates? (IMG:style_emoticons/default/flag.gif)
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bryanc
post Jul 29 2006, 09:11 PM
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When I was looking for a race car, I found a fairly nice one that had a torn ear. I pointed it out to the owner who.... um .... look surprized. He had been at California Speedway the weekend before and figured that happened up on the oval.

He wouldn't take any off of the price though..... I bought another car.
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Brad Roberts
post Jul 29 2006, 09:22 PM
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What I dont understand: (IMG:style_emoticons/default/confused24.gif)

Who installed the PolyBronze stuff and DIDNT inspect EVERYTHING while under the car? There is NO way this occured in one day.

Every time I'm under a 914 I clean the ears off enough to inspect them.



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ChrisFoley
post Jul 30 2006, 09:16 AM
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Brad,
With the engine in place and with all the undercoating on this car it would be very difficult to pick this up in advance of failure. Maybe on the passenger side it might have been found because there is definite perforation visible on close inspection.

The number of un-bonded spot welds means the console flexed more in cornering than normal. That led to failure at the most highly stressed location. I bet the crack only started to propagate late last season.

I got the inner portion of the ear welded back on but didn't have time to make the patch piece for the rusted out segment. Hopefully I can finish the drivers side and get the pass. side done, reinstall the engine and align the car for next Saturday.


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ChrisFoley
post Jul 31 2006, 06:39 PM
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I made good progress today. (IMG:style_emoticons/default/smile.gif)
Here's the console with patch installed, ground down and coated with weld-thru spray.


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ChrisFoley
post Jul 31 2006, 06:41 PM
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After that I added the reinforcing piece.


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ChrisFoley
post Jul 31 2006, 06:42 PM
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Here's the outside view.
After a coat of black paint I can reinstall the trailing arm.


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