Strut Tower Crack

Bernie Benz b.benz at
Thu Jan 17 17:47:16 PST 2008


You say, “Also, some cracks haven't yet reached the hole.“ What are  
you talking about? It’s your hole, put it where you wish. I wouldn’t  
repair such a crack by welding. Just a hole and a strut brace.


On Jan 17, 2008, at 5:33 PM, S. C. wrote:

> Thanks for your input, Bernie.
> What if you were going to try to repair the crack without welding?
> Also, some cracks haven't yet reached the hole.  Or they did reach the
> hole, but haven't gone beyond.  In such cases, would you recommend
> doing nothing?
> Sean
> On Jan 17, 2008 7:15 PM, Bernie Benz <b.benz at> wrote:
>> 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.
>> Bernie
>> 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
>>> _______________________________________________
>>> 200q20v mailing list 
>>> 200q20v

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