Appreciate the input and insights Daniel.

I'll be taking a hammer to it today and see what happens.

I considered shaping a piece to fit and welding to the surface away
from the hole. And for sure, I agree. A "plug" butt weld would have
been a waste of time. I would have over lapped the piece if I had
tried.

Thanks for the help!

Neil.

On Fri, Sep 5, 2008 at 6:39 AM, Daniel O Stevens <dosteven@syr.edu> wrote:
> Neil,  that rear trailing arm would do it's job if it was 1/2 the original
> size (and properly curved/contoured)
> but that rust is not new, not even the little spots further opened up.
>
> Yes it gets a pushing load from the wheel
> yes it gets a dragging load from the vehicle (trialing arm).
> yes it gets a torqueing twist from road potholes and hard turns.
>
> and yes I would NOT discontinue my immediate trip over this, but would avoid
> rock climbing and curbs
> and just drive it easy, more so to ease your own concerns.
>
> I am not an expert in mechanical design, but I do play one on the weekends
> having designed my own rear suspension for my baja bug to allow 36" tires
> and a smooth ride
> I have put great thought into trailing arm design. and I have less weight
> but allot more abuse and stresses
> (can't see arms in this image, but can see some work I put them thru, I am
> still on my 'prototypes'
> http://images.thesamba.com/vw/gallery/pix/269984.jpg)
>
> as for MIG'ing that piece don't look at it as a body panel 'plug'
> replacement
> WRAP a repair well past the weakness just like a 'bandaid'
> heat it up and beat it to match the curve of the piece, and if you have to
> remove some of that ridge
> it's ok.. Syncros with ~30" tires have to remove that ridge ALL the time
> (own one of those too)
> and they put far more stress on the arms..
>
> one place that WOULD WORRY ME, that is often OVERLOOKED
> the rear spring mount post on the trailing arm often corrodes and severs
> from the arm.
> this would allow the spring to spit out of the arm that that would be VERY
> BAD.
>
>
>
>
>
>
> ate: Thu, 4 Sep 2008 19:59:55 -0700
>
> From: neil N <>
>
> Subject: . Whining Content + Warning (PICS)

> But the issue in the pic below was on my mind. Pulled over just before
>
> the border to check it:
>
> http://tubaneil.googlepages.com/TrailingArmHole1.jpg/TrailingArmHole1-full;init:.jpg
>
> While checking, I poked below. It now has little brothers:
>
> http://tubaneil.googlepages.com/TrailingArmHoles.jpg/TrailingArmHoles-full;init:.jpg
>
> I did a LOT of work getting Jaco ready to travel, but couldn't see
>
> driving it 2000 miles + this way. I know. It might have held, but it
>
> was accelerating in it's growth.
.....

> I AIN'T no expert and DON'T know how long a trailing arm in this
>
> condition would be ok. But, I couldn't help but see in my minds eye,
>
> all that weight and torque opening that hole up progressively faster
>
> til it failed.
>
>