Album Index for Album 0007: Chassis Braces $2.85

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update: If I were do this project again, I'd use flat aluminum bar stock or channel for the front brace I'd also weld onto the lower a-arms in the rear and tie in longitudinal braces ala the '94+. 
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Here is the problem.  The standard Moss/PBC/Finish Line rear chassis brace won't clear my custom 2 1/2" catback.
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Here is the stock.  The braces cost about $80 shipped.  Enough 1" tubing from the welding shop to do TWO sets of braces front and rear cost $5.70!
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Close up of the originals.
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Starting on the end in a press.  Later, I started on the inside instead and worked outward making two passes.
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Mushed! If you have a 20ton you can probably do it with a plate on top...ours was only a 6 ton.
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I then press from the back side to straighten it.
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Ugly marks?  NO problem. See the next pic.
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Some ball peen bashing flattens it right out and gets rid of the marks...as if anyone cares what it looks like!  If they see it, you just ran over them! ;-)
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There we go!
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One front brace, ready for holes.
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OK, let's bend the rear braces.  Seal the end.
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The obligatory pretty MIG shot.
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Fill the tube with sand.
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Tap, tap, tap.  Get as much sand in as possible.
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Seal the other end.
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Heat it red hot and bend.  It still wrinkles a bit on the inside, but is plenty strong enough.
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Tie a pair of braces 'round the ol' oak tree....  Be glad you can't hear me sing.
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Flat black, just like my exhaust.  Note we did drill holes.  MARK them carefully before drilling.  I still had to use a round file for a tiny fix.
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Three sets.  The original on the left. A set for my buddy Scott's '90 in the middle.  A set with an extra bent and non-parallel squish for my '91 on the right.  The cup of water is for my burnt hand.
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Here's where the front brace bolts up.
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My '91 has quite a bit more space UNDER the wishbone than my buddy's '90 did.  I couldn't get a wrench in his at all.
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It's amazing how much cowl shake is reduced.  On my '91 the 65mph shimmy is also removed.
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You DID make marks so you don't change your alignment, right?!?
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Use a torque wrench.  These go pretty tight...you don't want any surpise toe on the rears in the middle of a performance turn.  Is this as good as a Skip Cannon?  NO!  But it cost $2.85, remember?
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Hundreds of people have asked to see Hakuna, so here is a picture.  (actually, no one asked, but it was a good pic!) Update: This is an OLD pic, see the Zaino section to see what Hakuna now looks like.