I've had a number of structural problems in the last 2 years since adding a 21mm SCA rear sway bar. First the OE mounting points deformed, then cracked. Then I used Stazi's weld-in reinforcement plates to convert to a 2-bolt setup, but these plates' welds then cracked. Then I drove around with no bar for a while
ATI Motorsports (www.atimotorsports.com) fixed the problem right. The fix went like this:
1. Drop rear subframe. In my case we dropped the subframe and knuckles, disconnecting the longitudinal link at the knuckle, but leaving the lateral links connected to the knuckle.
2. Completely remove existing sway bar mounts with a Sawzall. Man, did those things ever look 'optimized' (meaning spindly and weak).
3. Build up new sway bar mounts with 1"-ish C-channel. The C was oriented so when installed in the car, it looks like a U from the back, so the middle leg of the C acts as the face that the bar mounts to. The beautiful thing about this fix is that a single piece of C (about 3" long) can be notched to fit into the existing subframe flange at the front of the subframe, then welded all around. So now I have a strong, stiff mounting point made of a single piece of metal - no need for lots of little scab plates to reinforce the OE mounts. ATI also put in weld nuts on both ends.
4. Reinstall bar and subframe into car. I used Prothane bushings and mounts. I added zirc fittings to ease lubrication.
5. Align. Interestingly, even though the subframe was reinstalled without the proper alignment pins, the initial alignment created by just bolting everything back together turned out pretty good, just a little bit out of toe.
6. Pay ATI $400 for their time (3.5 hrs R&R + 1.5 hrs align at $80 per).
6. Enjoy lift throttle oversteer
ATI was a joy to work with. They had no prior experience with this common Contour problem, but they were enthusiastic to take on a new task. Their shop in Novi, Michigan was beautiful and new. Current projects in there are a 911 getting a new coilover kit, a Mustang getting a new 4.6 2V, a 4.6 4V Focus wagon with an 8.8 rear end(!), a twin turbo C5 racecar, and of course their now-famous 03 Cobra powered Focus with IRS. Drool....
Then they took some measurements and decided that a 4.6 4V and 8.8 rear end could make my car into a rear-drive V8 demon for about $15k. Not my cup of tea...but anyone else?
I have pictures but nowhere to host them. Anyone want to help here?
