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.

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.

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

Nice job Now who gets the BILL????

Keep up the good work.

Nice!

Did you weld on the outside as well?

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

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.

Perfect timing for this thread. I'm getting ready to install a front sway bar soon.

Lookin sweet Mark!

Is that a ground tab in the area of the swaybar? Is that for the fuel pump on late cars?

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...

I wouldn't think that welding on the outside is required because the bushing/bracket fits there. Mark, can you confirm?

I thought the same, that somehow BRAG wound up on World.

Nice to see a clean install. I'll be doing that someday soon.

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.

BRAG

but yeah, sick work. I like to throw a few tack welds on em also...

Yeah, I think it came out pretty well...

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

Good work Mark. What about some reinforcing on the fenderwell side like the build in excellence. Any opinions out there?

That Looks great!

Engman sells a plate 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.

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.

63 $ incl shipping...they sure are nice though.

Nice work, Mark!

Solid! Good work!

Are the factory ones welded in place?

Yep, but I don't have a picture of them. They're spot welded, IIRC.

Mark, is that a new 914 to you ? I see it in your av. so I am wondering if your going green in 09.

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.

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

That's what I thought.

This is to be my first welding project on my car.

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.

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.

Click to view attachment

Click to view attachment

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?

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!

Don't 911 front bars run under the car and 914 thru body?

Some 911s have under body bars, some have through body. But I'm not sure about the interchangeability with 914s.