Front Control Arm Bracket Breakage and Repair (1 Viewer)

[Riad]

If your going to play in the rocks, stuff is going to get bent. Have only hit the panhard bracket a few times and bent it once. If it becomes a bigger problem will add a skid/gusset. Don't see how a Diamond would help, not bending the housing? To install a Diamond would need to ether cut off the stock brackets and weld to it or make new ones. In this case it would be much easier to beef up the stock bracket?

You are right about playing in the rocks. However, knowing Onur and seeing the kind of wheeling he does, my gut feeling is he will find a way to bend the housing (I think its already bent) and break the easily beefed up bracket again . I would hope/think the Diamond axle will open up a world of opportunity for him. But then again I have a hunch that he can bend that too

 

[OGBeno]

You are right about playing in the rocks. However, knowing Onur and seeing the kind of wheeling he does, my gut feeling is he will find a way to bend the housing (I think its already bent) and break the easily beefed up bracket again . I would hope/think the Diamond axle will open up a world of opportunity for him. But then again I have a hunch that he can bend that too

Too funny brother.....

Too funny.....

 

[rockclmbr]

Nice work man! Why don't you get Rick to weld some fancy brackets up for you with his little portable welder

We are finding the fracture point after wheeling our rigs hard and they begin to hit 10+ years of age.

 

[TrickyT]

Bumping a 10 y.o. thread back to the top. Same exact thing has now happened to me, either on HITR trail this year or maybe last. I could post up a picture to two, but they would look just like what @beno shows in post #1. Also running Slee blue's installed with Rick's template. I see I even posted a reply in the original thread 10 years ago, although time and age have erased all memory of that. Plan to weld reinforcements plates on both sides of the stock bracket. Glad I caught this before something really bad happened. I was on the Rubithon run when @Inverness broke his bracket and it was a long trail repair. Bumping the thread for the younger crowd who may not be aware of this issue.

 

[cahill]

Nice thread revival. I had forgotten about this thread. Curious if anyone has follow suit with @Tools R Us and modded the control arms to limit contact with the bracket. How are yours holding up @Tools R Us ?

 

[rc51kid]

Old thread but good info. Last summer I broke the same braket the same way at cruise moab. I was running OME bushings. I replaced them with OEM bushings and landtank caster plates.

 

[Tools R Us]

Nice thread revival. I had forgotten about this thread. Curious if anyone has follow suit with @Tools R Us and modded the control arms to limit contact with the bracket. How are yours holding up @Tools R Us ?

Mine have held up fine, despite pretty much constant attempts to break them. When changing bushings, we narrow them ~.300" and narrow the stock arms to the same. Lots of them have been abused, the added space allows more movement, reducing the stress on the brackets.

 

[Jason Andrews]

I assume the crack down the front of the axle is that way stock since I don't see a broken weld. The OEM weld at the bottom looks to be developing a hair line crack though. What do you guys think? Should I just weld up the whole thing to add strength?

 

[Tools R Us]

When in doubt, weld it up! When we have axles out, take the opportunity to add gussets on the inside. Stiffens them right up, better than Viagra!

 

[cahill]

Mine have held up fine, despite pretty much constant attempts to break them. When changing bushings, we narrow them ~.300" and narrow the stock arms to the same. Lots of them have been abused, the added space allows more movement, reducing the stress on the brackets.

Thanks for the feedback and good to hear they are holding up. What are your thoughts on widening the bracket instead of shaving the control arm if you have to fix the bracket anyway? This would allow for the bushings to remain their original width and seems like it should work. I am sure you gave that thought before going your route and am curious what problems you forsaw with that plan that caused you to narrow the arms instead of widen the bracket?

 

[Tools R Us]

Thanks for the feedback and good to hear they are holding up. What are your thoughts on widening the bracket instead of shaving the control arm if you have to fix the bracket anyway? This would allow for the bushings to remain their original width and seems like it should work. I am sure you gave that thought before going your route and am curious what problems you forsaw with that plan that caused you to narrow the arms instead of widen the bracket?

Cutting the arms is easier, I'm lazy and have spare arms, so...

 

[inkpot]

Cutting the arms is easier, I'm lazy and have spare arms, so...
View attachment 1985296

Arms are MUCH easier to remove from rig and modify. We have done dozens of these with nearly zero failures so far.

 

[Cruiserdrew]

"nearly zero failures "

Explain "nearly"

 

[Tools R Us]

Explain "nearly"

Narrowing the bushings allows better flex, but also weakens them, so their life is shorter. I guess it's not really a fail, more of a cost of playing.

 

[junior80]

 

[TrickyT]

When in doubt, weld it up! When we have axles out, take the opportunity to add gussets on the inside. Stiffens them right up, better than Viagra!

View attachment 1985092

Ever done the gussets with the axle in place on the truck? Upside down welding would not be easy! Is the gusset just a flat piece of steel? Any interference problem between it and the control arm?

 

[bonestock]

Bump. Would like to see pics of how the bracket was reinforced. My USPS is cracked and weeping fluid.

 

[CharlieS]

I's also like to see the gusset a little closer. I'm refreshing my suspension once the weather warms up and would like to add some welds and this gusset as a preventative measure while I have the arms off.

 

[Delta VS]

@Outsane has some plates that can be added to repair/reinforce

 

[bonestock]

Just ordered these. Mine PS bracket cracked into the axle tube. Tried some quick welding to get on the trail today but, alas, we be for broken again. Axle tube seems to be OK but I’m ready for the plates, Lee!
@Outsane - got a thread on your plates? I searched(ish).