*HOW TO* Weld in Rear Brace
How to: Weld in Rear Brace.
A weld in rear brace is a much more efficient way of structually supporting/reducing chassis flex to the rear of any vehicle.
As detailed in the thread title, here's my "How To" with regards to doing this.
What you'll need:
MiG welder - Pref 100a minimum, IMHO DONT use a non-gas item as there sheet.
Suitable diamter/wall thickness tube - I used 38mm seamless, 3mm thick wall type. You will NOT need anymore then 1meter (1000mm) & dont be fooled into thinking a lesser 1mm wall tube will help, it wont. Get some hefty stuff at least!
Wire brush (maybe)
Welding mask (dont be tempted to close your eyes & hope for good results, in reality it never happens)
*Disclaimer: This is a How To guide ONLY. If your's end up coming out carp then its your own problem. I nor PNG or any of its affiliates accept NO repsonsibility to any eventual outcome of your welding skills and/or metal working abilitys. You will be carrying out this modification at your own risk. Do not complain to me if it goes tits up, this is my advice only. Using inferior/unsuitable/copper pipe to make a rear brace will result in majorleague ownage if used as a harness bar, nobody wants a windscreen in there face TBH really do they.
Now the boring bits over, lets get started.
Step one:
Get your steel tube cut to length @ 928mm or there abouts (definetly NO smaller though!) Anywhere between 928 & 930mm should ensure a nice snug fit between both inner archs (you may to tap it in with a hammer so it wedges itself).
http://i80.photobucket.com/albums/j1...ebuild/323.jpg
DO NOT use a Spirit level to get it level, as 99% the vehicle will not be parked on a garanteed level surface.
As you look at the inner archs, you want the brace inline with both shock absorber top mounts (take note where mine is) & the height is approx 135mm from floorpan.
Tak it in - Get the welder on the go, if using 3mm thick steel tube, gas mark 6 with a wire speed of 6.5 to 7 should see ample results. Bang a tak at either end, then measure it up against sizes quoted above.
Once happy, large it up with the welder.
http://i80.photobucket.com/albums/j1...ebuild/324.jpg
http://i80.photobucket.com/albums/j1...ebuild/325.jpg
As you can see above, results after using aforementiond wire speed/gas mark combined with a Proffesional Auto Darkening Welders mask. If your welds resemble birdshizzle, then learn how to weld properly & then come & consult this article. If you, like me, have nice flat, nearly even weld's then bothered.
Note: Welders start fires. Ensure the waxoyl/underseal/tar substance you painted in your wheel archs 10 summers ago hasnt caught fire :thumb:
Job done.
Or is it? Well no, fresh welds & untreated metal corrod instantly with moisture in the air. Coat it up with suitable primer (Etch/Zinc/Normal grey carp).
http://i80.photobucket.com/albums/j1...ebuild/326.jpg
Finished. Your now free to carry on with your life safe in the knowledge you can ebay your old bolt in strutbrace for about £25.
Whilst you here, Heres another little HOW TO on Welding in Roll Cage Spreader Plates.
Happy welding
Mike.
