Elephant Racing Swaybar Repair on 1987 911 Carrera

 

Most important is prep!  Get rid of all undercoating. This took 3.5 hours start to finish, not including sway bar removal.

Important Points:

  1. MOVE wires and lines FAR from the area and protect wires with thick gaffer’s tape.
  2. COMPLETELY remove the old mount. This is best done with a combination of wire weheel, falpper sander disck, cutof wheels etc.
  3. ENSURE you remove all undercoarting from at at least 1″ from the weld area. Use a wire wheel to remove the galvanization layer until it’s completely smooth and even reflectivity
  4. STITCH WELD Use 0.023″ wire or tig.  The sheetmetal is 18 ga or so so do not try to run a continuous weld and use the new bracket as a heat sink to avoid blow-through.
  5. Use 3M Brusahable Seam Sealer to cover it. We covered the holes in the ends of the bracket to avoid moisture intrusion
  6. PAINT – to Match?  Or black.

 

 

 

Also replaced tank sender