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I was showing off my recently rebuilt Verde to RacingSwim yesterday, and the torsion bar snapped right before taking a corner. Bad, but damage was minimal, and as long as it isn't too corroded in there (it is), it should be simple enough to repair.
Here is a photo of the cracked torsion bar - I'll upload a photo once I pull it from the car:
I'm fortunate to only have to replace the torsion bar, and I will definitely inspect and likely replace the other bar as a preventative measure. That being said, I'd like to never experience this kind of failure again. On the highway, it could have sent me into the median and spun or flipped the car.
Driver side torsion bar mount:
Passenger side torsion bar mount:
So, I'd like to address the rust on the welds that attach the splined torsion bar collars to the crossmember.
Option 1 is to just grind out the rust, assess the material thickness, and run a new weld bead around the joint. This might be an option, but I'm not so sure the metal will still be thick enough after grinding the rust out.
Option 2 is to grind the rust out, and then cut a new ring to lap weld to the cross member and weld to the splined collar. This is a bit more work, but seems like the prime path. While I'm in there, I think I'll spray something hydrophobic inside the crossmember to prevent rust from the inside.
Option 3 is to clean rust and then attach a reinforcement plate as was done in this case. I worry about the moisture wicking that might occur from two plates in close contact - is that a reasonable concern? : http://www.alfabb.com/bb/forums/mil...ear-torsion-bar-mount-spun-what-can-i-do.html
Option 4 is to swap in an early GTV6 forged (?) crossmember and run early GTV6 bars. I need to look into the bolted joint to see how much shear is on those bolts, but the LeMons guys seem to have success running this: http://www.alfabb.com/bb/forums/mil...lano-torsion-bars-sheer-genius-stupidity.html
All in all, it's a good chance to beef up the Milano, which at this point is getting waaaaay too much mechanical attention. This is easy stuff after all this car has put me through. Threw a rod on the highway with full oil level two weeks after I bought it. Threw an axle ,brake caliper and brake disc out of the car within the first 1,000 miles of ownership. Surprise clutch hose rupture the day I brought it home. Yeah, this car was seriously neglected, but it is slowly coming around and I am loving it :smile2:
Please share your thoughts!
Here is a photo of the cracked torsion bar - I'll upload a photo once I pull it from the car:

I'm fortunate to only have to replace the torsion bar, and I will definitely inspect and likely replace the other bar as a preventative measure. That being said, I'd like to never experience this kind of failure again. On the highway, it could have sent me into the median and spun or flipped the car.
Driver side torsion bar mount:

Passenger side torsion bar mount:

So, I'd like to address the rust on the welds that attach the splined torsion bar collars to the crossmember.
Option 1 is to just grind out the rust, assess the material thickness, and run a new weld bead around the joint. This might be an option, but I'm not so sure the metal will still be thick enough after grinding the rust out.
Option 2 is to grind the rust out, and then cut a new ring to lap weld to the cross member and weld to the splined collar. This is a bit more work, but seems like the prime path. While I'm in there, I think I'll spray something hydrophobic inside the crossmember to prevent rust from the inside.
Option 3 is to clean rust and then attach a reinforcement plate as was done in this case. I worry about the moisture wicking that might occur from two plates in close contact - is that a reasonable concern? : http://www.alfabb.com/bb/forums/mil...ear-torsion-bar-mount-spun-what-can-i-do.html
Option 4 is to swap in an early GTV6 forged (?) crossmember and run early GTV6 bars. I need to look into the bolted joint to see how much shear is on those bolts, but the LeMons guys seem to have success running this: http://www.alfabb.com/bb/forums/mil...lano-torsion-bars-sheer-genius-stupidity.html
All in all, it's a good chance to beef up the Milano, which at this point is getting waaaaay too much mechanical attention. This is easy stuff after all this car has put me through. Threw a rod on the highway with full oil level two weeks after I bought it. Threw an axle ,brake caliper and brake disc out of the car within the first 1,000 miles of ownership. Surprise clutch hose rupture the day I brought it home. Yeah, this car was seriously neglected, but it is slowly coming around and I am loving it :smile2:
Please share your thoughts!