Problem: Replace the rubber in the sway bar support bracket.
The rubber had deteriorated, perhaps because of a leaky power steering pump:
Notice the large spot weld on the third & fourth pictures. The normal procedure is to drill out the two welds and replace them with bolts after replacing the rubber block. In this case that would have required such a large drill as to leave little metal behind, so we used a reciprocating saw to make two cuts to remove the middle of bottom plate to allow removal of the hanger. Right picture is the hanger after grinding off the leftover pieces of the bottom plate with an angle grinder:
The next step was to make a new bottom plate. The first one didn’t fit, so I measured the error and laid out the second one that was wider by the amount of the error. The bends were adjusted for the best fit of the metal pieces. This resulted in a bit of pressure on the rubber which the mechanic thought was good:
CUT
Cut out
Piece
Left
Remminent of old bottom plate ground off
First layout
Second one fit
Didn’t fit
Bending
Trial assembled
Drill bottom plate through holes in bracket -
Drilling 1/4” hole
Drilling pilot hole
Installed
2 cuts to remove mid part of bottom plate
Hanger after ends of bottom plate ground off