TwistedPhil
+1y
Some quick tips:
-Use thicker material- the old mount looks like it was cut from 3/16", which isn't that thick- at least 1/4" should do.
-Make your gussets long enough to actually brace the control arm mount! Your mount broke right where the gussets end, because there's nothing above them but a flat piece of plate... not very strong! Even before this broke, it was probably allowing crazy camber changes as it flexed back and forth when you drove...
-PAINT IT WHEN YOU'RE DONE!! Take a little extra time finishing everything when you install it- grind the edges smooth, and use a 2 dollar can of black paint to keep everything from rusting! No offense, but even without that front end broken it looks unsafe!
If you're asking for advice, mine is to cut everything off of there and start fresh with some new material. You'll end up with a stronger and safer finished product than if you try to repair or rebuild what's there.
Good luck!
-Phil at FBI