Hey Todd, is that your sway bar mountiing plates beside the break? (Hard for me to get my bearings in those pics.) If it is I wonder if it played a role in this failure.

Don

Don, I really don't think so. I haven't had a sway bar on it regularly since putting the BFG tires on it well over a year ago. Even with the r888's, I don't need one anymore since switching to stiffer springs after Optima. The sway bar only add's about 75-100 in/lbs anyway.

Good discussion, lots of concern, lots of opinions.... But you hit the nail on the head, and I'm glad it came to this final thought. "Original GM frame rail metal thickness and over usage for intended design"

Based on your attention to detail, It will be 10x stronger when you are done with the repair. I like your style.

Brett

See, you never have to wonder what is next on the car, it will always let you know what it wants.

That blows but glad you found out now brother---I will keep an eye on mine in the future once the car has sticky tires and more than 238 Ft Pds.

Rodger's car must have been faster and had more torque, his broken frame rail was like way more broken than yours. :lol:

Let me know if you are def coming out for the Calif Speedway deal---my place is available if you need it--hoping to have my car ready for that event as well.

D

No, No... that's not always true for everyone. Only if you have an Apollo type relationship with your car. :rofl:

Big Wanda, I'm making that race! Not sure I want to drive to Lake Forest every night. Thanks for the invite....:cheers:

Here's a quick design for a gusset. My thought is to over lap the cradle the same distance on each side of the outside of the frame. Along with a diamond shape that would be welded to the cradle on the bottom side, tack welded in every hole, and welded to the top of the frame rail/body. I'm also going to radius the sharp outside edges so I don't create any points.

The current crack will be tig welded and ground smooth.

I'll likely make it about another 1" longer to cover the body plug hole and get closer to my sway bar mount. Let me have it....
http://i200.photobucket.com/albums/a...rameGusset.jpg
http://i200.photobucket.com/albums/a...Gusset1004.jpg

That's a good plate design,I would use the same amount of holes only around 5/16 dia. A plate w/9/16 hole's might allow the surport plate to fracture sooner(plus larger holes mean more welds and more heat it the weld zone..A smaller hole will allow the plate to provide more of the surport needed.Keeping the end's of plate angled will not let the frame rail shear as easy.:thumbsup:

I agree but, tie it in to the sway bar mount and weld it out too.

"My old man is a TV repair man, he's got an ULTIMATE set of tools,....... I can fix it!":unibrow: