Just an FYI to let you know we just got in an new batch of 20 Sport Suspension Cross-Braces.

The replaces that bent-and-beat-up round tube you have crossing the front of your motor.

This new batch is among the nicest we've seen - we have a new machinist making them for us and he took extra pains to keep them scratch-free and the workmanship is top notch.

Here is the page where you can order yours (and there is more info about them too) http://www.928motorsports.com/parts/crossbrace.php

And here follows a few pics from this new batch...

 

FWIW, the bolts that are included may hit the underside of the hood, BTDT
The low profile Porsche bolts will clear it,
you wont realize this until you press the sides of the hood down and see it wont close any further then you will find a round indentation or paint chip on the hood.
The ones pictured on your S4 car look to be low profile,
the ones on the web page appear to be higher profile

 

I never considered myself to be a great welder, but I can do better than that pretty consistently. The rest is good work so I'd look for a better welder. Failing that you can overfill , grind, and polish. I'll wait until you sort it out to order.

 

I was welding aluminum that good about the end of my second go at it.

 

I'm guessing you had already mastered puddle management using another method. Out of position stick or gas prolly. Sad thing is these are roll outs and should be very pretty. No offense to the OP and I would really be in the market for one of these if the welds were better.

 

I agree with the comments about the welds. I would say that the welding should be followed by "final machining" to make them look pretty. Finally, I would prefer that the inscription refer to the car and not the manufacturer i.e. "Porsche 928S4" instead of "928 Motorsports". I've always objected to carrying somebody's advertising around on my car. I have my U.S. Army outfit on my back window and that's it.

 

I have one on the old very brown 1980 might just be the nicest part of the car ! thanks Carl.

 

Couldn't use PORSCHE, but maybe could produce 928 S, 928 S4, etc.. inscription.

Looks sturdy. Would definitely go for it even with 'Motorsports', but you have to clean up the welding.

 

Welding Aluminum is not easy, making it look pretty is even harder....
I would make some with no inscription at all, just have it smooth like the factory.

 

Merlin - yes, since you experienced your problem all the fasteners we provide have low-profile top caps.
You are right, the pick on the S4 shows this.

All - very surprised that the welds do not meet with favor. Done by the professional welder that we use for all our most demanding aluminum welding. Note they are not "cleaned up" or ground/sanded on. I'll see if I can get you a better pic of just the welds.

 

As a welder, alum is funky to say the least. Top pic they look alright, second pic bottom left looks fugly. but could be the lighting. im willing to bet the mount it solid and the bar is thin. you have to be super hot to melt the bottom bracket without completely melting the bar....

 

That was my thinking as well. The difference in thickness mass of the two parts made it difficult to control the puddling but better to be functional than too pretty. I have seen beautiful tig welds which broke/failed due to poor penetration. And you never want to be guilty of poor penetration !

 

As a complete and utter non-welder, I don't have any tech to add, but during my stay at the holdiday inn last night, I came across this thread at garagejournal. Carl, you should hook up with this guy: (check the aluminum dash work in post #6


http://garagejournal.com/forum/showt...aluminum+welds

 

Carl..its....they just stand OUT so much, its a mental challenge to not be drawn to the craggy welds, that's all.

 

If you powder coat them, the welds won't bother you so much.

(All the photos in this post are from an older batch than what Carl is selling now, but ... no regrets. I like these, both old and new. And, FWIW, I got mine back in May and it came with the low-profile, button head bolts.)




The engraving on the new ones looks nicer than on the previous batch. The old engraving was really subtle when powder coated.




IMHO, they look nice when the finish is matched to the other stuff in your engine bay.