Small car related welding task

[sport1901966]

Hi guys, thought I'd post up my latest welding job hoping for some input on the welding.

Background - My 306 HDi keeps snapping engine mounts due to excess movement as there is too much clearance between the mount buffers and chassis, the pic below shows this but after I have welded the plates in (imagine the clearance if they werent there)

I decided to weld in some plate to fill the clearances, ~5mm at the front and ~3mm at the rear, the chassis panel thickness around here is 3mm. THese are the plates

The cradle before welding

The front plate welded on

and the rear plate welded on

I did a test of 5mm onto 3mm prior to starting and I couldnt break it off so I went ahead. I'm pleased with the top welds but getting to the sides was a right pain.

I finished it of with galv spray and top coat, the final assembly turned out as above. I'm not sure if the breaking mounts are no more as the repair was only done a few days ago, but it certainly feels a million times better to drive!

Cheers for looking!

 

[kelsham]

Hi, I am a little concerned that you may be treating the syptoms rather than the cause.

I trust you have checked and replaced all the mounts and stabilisers?

It seems unlikely that a modern day manufacturer would make a basic error in providing the wrong clearance?

Of course you may know better?

Regards Kels.

 

[sport1901966]

It's a fairly common issue with higher powered 306's. Added to the vibration of a diesel engine it obviously stresses the mounting to its limits. The buffers shown in the first picture clearly are there to reduce longtudinal deflection of the mount but the clearance seems to vary from car to car and mine is particularly high. The modification I have done is a very common solution.

The lower engine mount is due to be replaced and I have the new part to replace it with which will help the issue but finding the time and equipment (a high tonnage press is required) is not easy at the moment. With any luck taking up the movement of the engine at the top mount should save the upper mount for the time being.

The main thing I was hoping to get was some criticism on the welds.

 

[Sphinx]

I think that's a good idea and the weld look damn good considering positioning must have been a pain!
As for modern manufacturers making basic errors, I would agree with that statement in all cases other than French manufacturers. I'm not just jumping on the clarkson band wagon when I say that as I've owned a few french cars and their design leaves a lot to be desired in some cases.