Strut Tower Crack

Bernie Benz b.benz at
Thu Jan 17 16:15:17 PST 2008

If I were going to repair this crack by welding:
First, I would never try to weld a ¼” thick plate to the 16 Ga.  
material. Such a patch should be close to the same material  
thickness. Further, tack welding in discontinuous spots around the  
perimeter of the patch is better practice than is a continuous bead  
around the patch.

I would drill a hole at the end of the crack prior to welding and  
then just weld the crack without adding a patch, up to but not over  
the drilled hole. This prior to adding a properly stressed strut brace.


On Jan 17, 2008, at 11:37 AM, Sean Coriaty wrote:

> My 1st 200q20va (now deceased) had the stress crack and my current
> 200q20va has it also.  I had the 1st one fixed; current one is
> spreading and needs attention ASAP.
> First time, a shop cut a piece of 1/4 inch sheet metal, placed it on
> top of the crack (overlapped crack by at least 3/4 inch all around)
> and welded it directly on top of the stress crack- but not all the way
> around the 1/4 inch metal plate.  They welded only 3 points around
> perimeter of metal plate.  It was explained to me that welding the
> entire perimeter wouldn't allow necessary flexing of that area and
> could lead to cracks in other areas.  It seemed to do it's job (no
> crack spread or new cracks) for a year before the car hit an uninsured
> phone pole in blizzard conditions.
> The first fix had minor issues- was a messy job, and surface rust
> quickly appeared on metal plate and around crack.  If I did it that
> way again, I'd try to ameliorate these problems.
> Now pondering how to have the 2nd crack repaired.
> Welding along the stress crack is not a good idea, as it will likely
> lead to another crack paralleling the weld (I'm told).
> The fact that Bernie's high mileage car w/ Bernie bar has no crack
> does not necessarily mean that the crack would have occurred if the
> bar wasn't there.  I've seen several 200q20v with high mileage, no
> Bernie bar and no crack.  But on the other hand, I've not seen a high
> mileage 200q20v with Bernie bar and crack.
> I have before and after pics of the first crack repair if anyone is
> interested.
> Sean
> Freedom, NH
>> ---------- Forwarded message ----------
>> From: Oscar Murphy <omt160 at>
>> To: 200q20v at
>> Date: Wed, 16 Jan 2008 13:51:17 -0800
>> Subject: Strut Tower Tear
>> What is the proper procedure for repairing the known torn strut tower
>> issue on the 200 20vs?
>> TIA-Oscar
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