Ugh...

[tdskip]

And it was all going so swimmingly too....

Started cleaning in prep for welding on the extra gusset when I found the following, look closely at the "face" of the bracket;

 

[Don Elliott]

What car is this photo from ?

 

[TR4nut]

DIdn't the 4A have only 1 hole initially for that mount which is a recognized issue with these cars? If so my guess is this is a less than professional modification to the front end to adapt to 2 holes as in the later cars. Just grind away a little and you should be fine?

 

[HerronScott]

The adaptation for a TR6 mounting bracket is to have a second hole below the first hole. This just looks like a bad repair where this mounting point started to tear at some point in the past.

Are you going to try and grind this down? Your other option would be to replace the whole mounting point. What's going on with the second hole since it seems to be blocked from the back side? Is there additional "work" back there?

Scott

 

[tdskip]

Hi guys - the picture is of my 1968 TR4A IRS. Same car with the squared-off brake rotor, so I cam guess is that when the wheel came off and the rotor hit the pavement there was enough of a shock/stress that it likely tore the bracket metal where the stud goes through. Sound right? Other ideas?

The back side of the bracket seems to be intact, so much so that I didn't notice the front side until I started cleaning it in prep for the strengthening gusset.

 

[PeterK]

Sounds logical. If the bracket is intact, you can probably grind it smooth and fill with more weld where required. Then drill the lower holes for your 2-stud setup. Keep in mind that if you face it with new metal, it would affect the alignment shims required.

New frame brackets have 4 holes drilled. Rear-most holes upper and lower are used for the 2-stud mounting. But it sounds like you don't need new frame brackets. At least I hope not. It's hard enough to weld the gussets in that confined spare.

 

[tdskip]

At least I hope not. It's hard enough to weld the gussets in that confined spare.

Me too! Not really looking forward to this repair, but it has to be done.

I'll go after it with a grinder and then take some pictures later today/tonight.

 

[DNK]

Tom- You've seen the info on the strengthening this area?

 

[tdskip]

Hi Don - I'm aware of the write ups but haven't actually done it yet.

I did order the reinforcements from TRF today.

I got in there with the "finger" grinder tonight and it now looks like this;

It appears that when the accident happened the bracket tore, and then a new plate was added in the back, and then someone who'd been drinking heavily took a MIG to the front of it. I believe the surface you are seeing is the original bracket face, and the surface behind is the other one that has been added.

Do the flat reinforcement plates go on the front or back? If on the back, any ideas on dealing with my situation since I already have an extra plate in the back that isn't flush with the original bracket?

Would you guys add the flat plate in the front and then the side gusset?

Thanks!

 

[tdskip]

Rear side of the bracket in question;

 

[PeterK]

Looks like they added the inner plate and the top plate to fix the damage although the bracket itself looks secure to the frame. I'd want to clean off the undercoat and examine the welds though, just to be sure. And add the gusset when you get it.

 

[tdskip]

Re: Ugh... TR4A Front Suspension Bracket

Good morning Peter! Fortunately the bracket itself is still firmly attached to the frame.

So I have four DC49 in route from TRF.

These are designed to mount in the rear (engine side) of the brackets, correct? Since they fit in the back of the bracket welding on the gusset side reinforcements can be done at any time since they don't actually interfere with each other, correct?

Thanks guys!

 

[PeterK]

Re: Ugh... TR4A Front Suspension Bracket

Correct. DC49 is a square thick mild-steel washer with 4 holes. They go inside DC48. The mounts use the rear most set of holes.

On your damaged bracket, you already have the POs backing plate so you might not need one there.

 

[HerronScott]

Re: Ugh... TR4A Front Suspension Bracket

Peter,

That's what I was thinking as well.

Scott

 

[tdskip]

Re: Ugh... TR4A Front Suspension Bracket

Thanks for the confirmation guys. Just for grins I poked at the backing and it fell out. Turns out it wasn't even welded in place!

 

[tdskip]

Re: Ugh... TR4A Front Suspension Bracket

Gusset in welded in place....

(ugly but should be strong welds)

Next up, dressing the welds and touch up. I was thinking of waiting until I have the correct backing plate reinforcement welded in place before trying to to fix the front mounting hole area. What do you think?

 

[DrEntropy]

Re: Ugh... TR4A Front Suspension Bracket

"Ugly"??? I think not! My welding looks like your PO's whether I'm drinkin' or not. Friends call'd it hen -poop-...

Wait 'til you have the backing bracket secure before you dress it up any more.

:thumbsup:

 

[HerronScott]

Re: Ugh... TR4A Front Suspension Bracket

Note that I don't believe the backing plate reinforcement is typically welded in. I would wait though before doing any cleanup around the holes since hopefully the backing plate reinforcement can serve as a guide for the hole locations. I made my own so I don't know how tight-fitting the pre-made one is going to be inside the mounting point.

Scott

 

[tdskip]

Re: Ugh... TR4A Front Suspension Bracket

Wow - I just <span style="text-decoration: underline">assumed</span> they are welded in place Scott. If they are just a tension fit that would be nice since it would save a bunch of time

 

[bgbassplyr]

Re: Ugh... TR4A Front Suspension Bracket

They will be sandwiched between the bolt head and the existing bracket. After all is bolted up, you might just tack it at the corners to stop any future 'rattles'.