factory rear sway bar conversion question

[crash340]

Oh wise ones,

I have a set of Urethane rear frame sway bar mount bushes and saddles (slotted for bolts version). I have drilled the spot welds on the old bushing brackets to remove them and the old tired bushes.
I now have nice clean frame bracket 'U' plates, I would like to retain them and the 4 screws per that hold them onto the frame rail, however, I want to fit the new Urethane bushes and saddles. Any suggestions on how I can do this, my first thought was a pair of sheet body screws similar to those that hold the U bracket onto the rail but have read its a weak option. What if I drill and tap the factory frame bracket for say a 3/8" threaded stud, grind a chamfer on one end, screw that end into the frame bracket and plug weld it of sorts from the back, grind the weld flush so it can be bolted back onto the frame using the existing screws, from there just use washers and nylock nuts to hold the bush saddle in place. Will this be strong enough??? I dont really want to go out and get a set of frame brackets as they are rare down here.

Whats my best option with what I have, appart from welding the saddle to the frame bracket please.

Greg

[brads70]

What about using these....
https://www.google.ca/search?q=flat+head+socket+head+cap+screw&source=lnms&tbm=isch&sa=X&ei=Qf87U86KHu2G2wXj34HYCw&ved=0CAYQ_AUoAQ&biw=1024&bih=689

[crash340]

Thanks Brad, I have though about using the counter sunk, drill and counter sink the frame bracket, weld them in place, grind suplus weld off etc. I should imagine it wont pull though the frame bracket?

Greg

[brads70]

Maybe make a thicker bracket/flat plate to support the countersunk head and mount it either behind the frame U plate floating or weld it to the U plate  on top?

[crash340]

Have had a thought!!!!!

maybe I put the factory bracket back on the chassis rail with the factory screws (4 each bracket) for orginality looks as such, then drill two holes in each face and fit a nutsert and bolt the bushing saddle to the bracket/chassis rail, say 7/16", or maybe fit the nutserts to the chassis rail then fit the factory bracket over them so they cant pull out through the bracket etc? if you get my mumbo jumbo

[brads70]

As long as they didn't spin it would work?

[Road_Runner]

Have had a thought!!!!!

maybe I put the factory bracket back on the chassis rail with the factory screws (4 each bracket) for orginality looks as such, then drill two holes in each face and fit a nutsert and bolt the bushing saddle to the bracket/chassis rail, say 7/16", or maybe fit the nutserts to the chassis rail then fit the factory bracket over them so they cant pull out through the bracket etc? if you get my mumbo jumbo

Any chance those would interfere with the bolts securing the bracket to the frame?  I'd probably be more inclined to weld a flat headed bolt to the frame bracket and secure the outer bracket holding the bushing with washers & lock nuts.  Plus you wouldn't have to drill the holes into the frame for clearance, maybe just dimple the face of the frame to make the brackets fit flush so everything align with the original bolt holes, etc.

Later, Jim

[dfrazz]

If it is like my aftermarket rear ant-sway bar, I shimmed the bracket out from the frame rails.  If I mounted the bracket higher (towards the trunk floor) the bar sat too low so I had to move down the frame rail which separated the bracket due to the angle of the frame rail.  I also welded a bracket on the rear and attached the linkage to it so I could remove the entire anti-sway bar without having to break the bracket off the rear.  I hope this helps.