I've seen those suspension kits, by chassis engineering, that say directly-threaded rod ends are weaker. They include these tube inserts... from what I get by the pictures, the tube inserts are welded into the steel tubes, then the rod ends are threaded into the tube inserts.

So, how's the welding done? Do the inserts get put into the tube, and the outer circumference is welded? As in, the welding's done where the outside of the tube insert meets the outside of the tube. That doesn't seem too strong to me, so I don't think it's right. That would mean that the tube insert is only welded at the edge. I came up with two other ways...

1. Holes are drilled thru the end of the tube, perpedicular to the tube. Say, two thru-holes are drilled, that leaves 4 holes, each 90 degrees apart, about an inch down from the end of the tube. The tube insert is placed into the tube, and then the insert gets welded to the tube by using the four holes. I guess then a weld's laid around the outer edge, where the insert meets the tube (as in my inital "too weak" guess).

2. The end of the tube gets slotted. A hacksaw's used to cut from the edge of the tube, say, an inch long, resulting in two slots... kind of making the end of the tube look like a "Y". Then, the tube insert is placed inside, and the slots welded. Then, where the insert meets the outside of the tube is welded.

Am I right on either (or all 3, hehe) of these guesses? Thanks in advance!! I should probably buy a chassis fabrication book, eh?


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-Tom P (Hot rodded 1986 Firebird 2.8l) from http://www.f-body.net/mailbag/3rd/3rd_mailbag.html message boards
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