Help with upper stress bar install

[rocco16v at netzero.net (L F)]

Andrew,
  After looking at the pic, here's what I'd do:

Weld up the holes in the bar and redrill them closer to the tubing.  You may have to grind a little clearance in the pad-to-tubing welds, but I believe you can gain enough room to make it....it's not that far off now.  Do this on BOTH ends.

Then, pull the struts and put in new upper bearings.  This will also serve to replace the missing/broken studs.

..and clean the leaves out of the rain tray.  :)

What do the rest of you think?

Larry 
sandiego16v
  ----- Original Message ----- 
  From: Andrew Wong 
  To: L F 
  Sent: Monday, May 26, 2003 6:17 PM
  Subject: Re: Help with upper stress bar install


  Here are the pics:
  <http://images3.fotki.com/v25/free/aae1/6/61168/260919/P5250038-or.jpg>
  <http://images3.fotki.com/v25/free/aae1/6/61168/260919/P5250039-or.jpg>
  <http://images3.fotki.com/v25/free/aae1/6/61168/260919/P5250040-or.jpg>
  It looks like its less than 2" and more like 1/2"  
  --- L F <rocco16v@netzero.net> wrote:
  > Well, how wide????  1/8"?  2"? 
  >  Don't bend the bar, that will defeat the
  > purpose....
  > 
  > Larry
  >   ----- Original Message ----- 
  >   From: Andrew Wong 
  >   To: L F 
  >   Sent: Sunday, May 25, 2003 9:06 PM
  >   Subject: Re: Help with upper stress bar install
  > 
  > 
  >   I'll have to take pictures of it to show how wide
  > it
  >   is, but I can get it to held on one side, but the
  >   other it is slightly wide where it looks like if
  > the
  >   bar can be bent it would be able to fit.
  >   --- L F <rocco16v@netzero.net> wrote:
  >   > Without having any more details, I'd venture
  > that
  >   > you could 
  >   > A) widen your Scirocco by the appropriate
  > amount. Or
  >   > B) cut a corresponding amount out of the
  > stressbar
  >   > and weld 
  >   >      it back together.
  >   > C) How much too wide is the bar?  Can you drill
  > new
  >   > holes 
  >   >      in the bar's bolt pads?
  >   > 
  >   > The broken stud can be pressed/hammered out and
  > a
  >   > bolt can be used in it's place.  If you want to
  > do
  >   > it right, pull the strut, disassemble it, and
  > weld
  >   > the bolt into the bearing housing from the
  > bottom. 
  >   > If you feel like tricking it up a bit, replace
  > all
  >   > four of the studs, which are 6mm, with 8mm
  > bolts. 
  >   > The 8mm will be a much more precise fit in both
  > the
  >   > tower holes and the stress bar holes, and you
  > can
  >   > safely torque them down more, to hold things in
  >   > place when the lateral forces from the bar start
  >   > occuring.
  >   > 
  >   > Larry
  >   > sandiego16v
  >   >   ----- Original Message ----- 
  >   >   From: Andrew Wong 
  >   >   To: scirocco-l@scirocco.org 
  >   >   Sent: Sunday, May 25, 2003 1:35 PM
  >   >   Subject: Help with upper stress bar install
  >   > 
  >   > 
  >   >   I got a neuspeed upper stress bar for 20
  > dollars
  >   > from
  >   >   an 84 GTI, it doesnt fit my 84 Scirocco, it
  > looks
  >   > like
  >   >   my scirocco is to narrow for it and also when
  > I
  >   > went
  >   >   to unscrew the bolts, one screw broke off b/c
  > of
  >   > rust.
  >   >    What should I do to install it?
  >   > 
  >   >   =====
  >   >   -Andrew Wong 
  >   >   1984 Black Scirocco
  >   >   1987 White Quantum wagon
  >   > 
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  > 
  > 
  >   =====
  >   -Andrew Wong 
  >   1984 Black Scirocco
  >   1987 White Quantum wagon
  > 
  >   __________________________________
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  > 


  =====
  -Andrew Wong 
  1984 Black Scirocco
  1987 White Quantum wagon

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