I have and easier solution. Drill a hole and tap in the
end of the broken link. Then insert hardened bolt. Cut off
and your done.

            Eric                   86-VW4x4
            vw4x4@fyi.net          72-240z
            Pittsburgh, PA USA     1936-Chrysler

On Fri, 19 Mar 1999, Richard A. Jones wrote:

> Keith:
>
> I thought there might be something in the archives about stabilizer
> links but didn't find anything with a quick check.  You might
> search further.
>
> Anyway, a year or two ago there was a lot of stuff on the web about
> stabilizer links breaking.  They do.  Someone stated it was the
> stress at the right-angle corner where the machining stops.  I
> know mine (all 4 four of them over several years) broke there.
> My current mechanic and I talked to a local engineering firm--
> one man, into racing--who suggested welding a hard bolt onto the
> end--the head cut off the bolt, of course.  I had him make two
> for me--one for each side--since I had two broken remains.  We
> only installed one--driver's side, which broke 3 to 1 on the
> passenger side.  That's been 2+ years and the other hasn't broken
> yet, but when it does, I'm ready!
>
> I have intended to take a photo of the welded link and put it
> on my web page, but haven't remembered to do so....
>
> I paid $25 (per link) for this guy to weld the bolt shaft on--
> including the bolt.  ;-)  BTW--mine's an '81 and I have to admit
> to some jeep-roading in the mtns when it was younger....
>
>                                 Richard A. Jones
>                                 University of Colorado at Boulder
>
>