Hi, after reading through posts on here and other sites, I've been looking at improving the handling on my car, Mk3 Ibiza Cupra. So far I've fitted 20mm Rear Spacers, which made a huge difference to the handling and improved it so much, Ive got a Momo/Seat Sport Strut Brace on order to stiffen up the front but wanted to also stiffen the rear. After reading the posts on here and seeing other people make there own rear brace i decided to give it ago myself.
Ive made a little guide below including pictures and a step by step instructions on how to fabricate your own.
Parts Needed.
4x 10mm flat washers, £1.
2x 55.5mm Exhaust Clamps, £2-5.
1x 1m x 1" Alloy/Steel Bar, £5-10.
Tools Required
welder,
grinding tools,
wire brush,
hammer,
files,
tape measure,
ratchet & 17mm socket,
pliers,
hacksaw,
emery paper, (rough 80 grit sand paper)
Spray paint/clear lacqure.
Guide
1. Start by opening your boot and removing the parcel shelf.
2. Remove the black rubber caps on top of each rear strut.
3. Gently pull back the carpet at the top of the struts and there is a flat piece of metal attached to the rear arch. Use the pliers/hammer to flatten down this piece of metal as it gets in the way of the rear brace.
4. On each clamp you will need to flatten and bend in the sides slightly so that it sits between the strut top mount and the arch.
5. Once this is done attach the clamps to the struts (on both side) so that you can measure the distance required for the bar between the clamps.
6. Now measure the distance between the clamps adding approximately 5mm at each end, This will be explained later.
7. Now using a suitable bar (i purchased mine from wickes, however B & Q or any D.I.Y store should sell it), cut it to the lenght you have just measured.
8. Now you can remove both clamps off the vehicle.
9. Cut the bar to the length required not forgetting the 5mm at each end.
This is the reason for adding 5mm to each end of the pipe.
10. Now using a grinder/ cutting tool cut out a gap in each end of the bar to allow the clamp to sit.
11. This is a trail and error job so just take your time, cut out bit by bit until the clamp sits in the pipe.
12. File down the rough edges, and using the emery paper rub down the surface of the pipe so that it can be welded. Then Check fitment.
13. Once happy, tack weld the clamps onto the pipe, making sure that they are level at both ends.
Now back to the car
14. You will need to trim some off the corner of the clamp to get it to fit around the top of the struts, just on one side tho.
15. Now check that the brace fits in between the struts and is a quite tight fit.
16. Once happy with the fitment of the brace remove from the vehicle.
17. Weld the clamps to the pipe all around to ensure a strong weld.
18. File down all rough surfaces and rub down with the emery paper to give a smooth finish.
19. Now fit the brace to the vehicle.
20. Put the 'U' shaped clamps around the struts and through the clamps welded to the bar.
21. Using a nut and flat washer tighten up the nuts on the clamp by hand ensuring equal tightening on both nuts and on both struts.
22. Tighten up the nuts equally making sure not to over tighten them pulling the struts together and bending the strut towers. Refit strut top rubber covers.
23. Road test and adjust until happy.
This part is optional but will look good painted.
24. Mark the position of the nuts (i.e count the threads or paint mark them so that they go back on where you had them set-up)
25. Remove the brace and prep for painting. Giving a good rub down until all smooth.
26. Using spray paint in the colour of your choice, give it 2 coates of paint and then one coat of clear lacqure to give a shiney finish. Allowing drying time between each coat.
27. Once totally dry, refit the rear strut brace to the car, making sure you tighten everything up. Check and double check.
28. Refit the parcel shelf and all is done.
After leaving the brace on for a week or so, just recheck that all the nuts are still tight and everything is ok.
Well thats my guide all done, now enjoy
This is how my finished one looks in my car
The colour of the pipe is a faded silver and its not that bright its just the sunlight.
I take no responsibilty for damage to peoples vehicles as a results of following this, as it is only a guide. If in any doubt, dont be a cheapskate like me and buy one.
Thanks any comments welcome.
Ive made a little guide below including pictures and a step by step instructions on how to fabricate your own.
Parts Needed.
4x 10mm flat washers, £1.
2x 55.5mm Exhaust Clamps, £2-5.
1x 1m x 1" Alloy/Steel Bar, £5-10.
Tools Required
welder,
grinding tools,
wire brush,
hammer,
files,
tape measure,
ratchet & 17mm socket,
pliers,
hacksaw,
emery paper, (rough 80 grit sand paper)
Spray paint/clear lacqure.
Guide
1. Start by opening your boot and removing the parcel shelf.
2. Remove the black rubber caps on top of each rear strut.
3. Gently pull back the carpet at the top of the struts and there is a flat piece of metal attached to the rear arch. Use the pliers/hammer to flatten down this piece of metal as it gets in the way of the rear brace.
4. On each clamp you will need to flatten and bend in the sides slightly so that it sits between the strut top mount and the arch.
5. Once this is done attach the clamps to the struts (on both side) so that you can measure the distance required for the bar between the clamps.
6. Now measure the distance between the clamps adding approximately 5mm at each end, This will be explained later.
7. Now using a suitable bar (i purchased mine from wickes, however B & Q or any D.I.Y store should sell it), cut it to the lenght you have just measured.
8. Now you can remove both clamps off the vehicle.
9. Cut the bar to the length required not forgetting the 5mm at each end.
This is the reason for adding 5mm to each end of the pipe.
10. Now using a grinder/ cutting tool cut out a gap in each end of the bar to allow the clamp to sit.
11. This is a trail and error job so just take your time, cut out bit by bit until the clamp sits in the pipe.
12. File down the rough edges, and using the emery paper rub down the surface of the pipe so that it can be welded. Then Check fitment.
13. Once happy, tack weld the clamps onto the pipe, making sure that they are level at both ends.
Now back to the car
14. You will need to trim some off the corner of the clamp to get it to fit around the top of the struts, just on one side tho.
15. Now check that the brace fits in between the struts and is a quite tight fit.
16. Once happy with the fitment of the brace remove from the vehicle.
17. Weld the clamps to the pipe all around to ensure a strong weld.
18. File down all rough surfaces and rub down with the emery paper to give a smooth finish.
19. Now fit the brace to the vehicle.
20. Put the 'U' shaped clamps around the struts and through the clamps welded to the bar.
21. Using a nut and flat washer tighten up the nuts on the clamp by hand ensuring equal tightening on both nuts and on both struts.
22. Tighten up the nuts equally making sure not to over tighten them pulling the struts together and bending the strut towers. Refit strut top rubber covers.
23. Road test and adjust until happy.
This part is optional but will look good painted.
24. Mark the position of the nuts (i.e count the threads or paint mark them so that they go back on where you had them set-up)
25. Remove the brace and prep for painting. Giving a good rub down until all smooth.
26. Using spray paint in the colour of your choice, give it 2 coates of paint and then one coat of clear lacqure to give a shiney finish. Allowing drying time between each coat.
27. Once totally dry, refit the rear strut brace to the car, making sure you tighten everything up. Check and double check.
28. Refit the parcel shelf and all is done.
After leaving the brace on for a week or so, just recheck that all the nuts are still tight and everything is ok.
Well thats my guide all done, now enjoy
This is how my finished one looks in my car
The colour of the pipe is a faded silver and its not that bright its just the sunlight.
I take no responsibilty for damage to peoples vehicles as a results of following this, as it is only a guide. If in any doubt, dont be a cheapskate like me and buy one.
Thanks any comments welcome.
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